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maintenance - Polaris Brasil

1. EN Description Engine Lubricant 2870791 Fogging Oil 12 oz Aerosol 2876244 PS 4 Full Synthetic 5W 50 4 Cvcle Oil qt 95 1 2876245 PS 4 Full Synthetic 5W 50 4 Cycle Oil gal 3 8 l Gearcase Transmission Lubricants 2878068 ar 98 Synthetic Gearcase Lubricant amp Transmission Fluid 2878069 oa Gearcase Lubricant amp Transmission Fluid 2877922 Demand Drive Plus Fluid qt 95 l 2877923 Demand Drive Plus Fluid gal 3 8 l 2870465 Pump for Gallon 3 8 I Jug Coolant 2871323 Polaris Antifreeze 60 40 Premix gal 3 8 1 2871534 Polaris Antifreeze 60 40 Premix qt 95 I Grease Specialized Lubricants 2871312 Grease Gun Kit Premium All Season 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 I 2871460 Premium Starter Grease 2871515 U Joint Grease 3 0z 89 ml cartridge 2871551 U Joint Grease 14 0z 414 ml cartridge 2871329 Dielectric Grease Nyogel Additives Miscellaneous 2871326 Carbon Clean 2870652 Fuel Stabilizer 2872189 DOT 4 Brake Fluid 2871956 Loctite 565 Thread Sealant 2859044 POLARIS Battery Tender Charger 133 SPECIFICATIONS SCRAMBLER XP 1000 1000 EPS Maximum Weight Capacity 290 Ibs 131 kg includes operator cargo and accessories Dry Weight 740 Ib
2. Item Maintenance Interval Remarks whichever comes first Hours Calendar Miles Km Steering Pre Ride Front suspension Pre Ride Rear suspension Pre Ride Tires Pre Ride 7 Brake fluid level Pre Ride See Pre Ride Checklist on Brake lever travel Pre Ride z page 54 Brake system Pre Ride Wheels fasteners Pre Ride Frame fasteners Pre Ride Engine oil level g Pre Ride gt Air filter pre filter Daily Inspect clean often replace E as needed Air box sediment Daily Drain deposits when visible tube Coolant Daily Check level daily change coolant every 2 years gt Power steering unit Daily Inspect daily clean often if equipped Headlamp taillight Daily Check operation 85 MAINTENANCE Periodic Maintenance Chart Item Maintenance Interval Remarks whichever comes first Hours Calendar Miles Km gt Air filter Weekly Inspect replace as needed E main element b Brake pad wear 10H Monthly 100 160 Inspect periodically Battery 20 H Monthly 200 320 Check terminals clean test b Engine oil change 25H 1M E Break in oil and filter change see page 52 E Engine breather 25 H 1M 250 400 Inspect replace as needed gt Demand drive fluid 25 H 1M 250 400 JBreak in oil level check gt Rear gearcase oi
3. Vehicle Model Number Frame VIN Engine Serial Number Key Number SAFETY Safety Training ATV safety training is a top priority for POLARIS POLARIS strongly encourages you and any family members who will be riding the ATV to take a training course If you purchased a new POLARIS ATV in the United States your dealer provided information about the authorized ATV RiderCourse 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 INFORM
4. 144 MAINTENANCE LOG DATE MILES KM OR HOURS TECHNICIAN SERVICE PERFORMED COMMENTS 145 INDEX 0 9 4X4 Switch ussuu 24 32 A Access Front Compartment 51 Accessories 00 eee eee 128 Air Filter eee codecs aun 104 All Wheel Drive System 32 33 Auxiliary Foot Brake 99 B Battery Chargin cm es 122 123 Extreme Use 30 AH 31 Installation 121 Removal eis issir rajha 120 Storage xx a Seneca he 121 Belt Life oco rh 25 BOOTS ara ya PE e hed 8 9 Brake Fluid Auxiliary Foot Brake 30 Brake Fluid Main Brake System 28 Brake Lever iege me teen 27 Brake Foot 1 22e 30 99 Brake Hand Lever 99 Brake Parking 29 Brakelig it oo nessies renes 107 Brakes en m Rs 99 Break In Period 52 53 C Camber Adjustment 116 Cat BO n cos eese oe ol cd Re 68 70 Caster Adjustment 116 Check Engine Indicator 41 Cleaning and Storage 124 127 Clothiflg i egets 9 Clu tching isa swar e 135 Cold Weather Operation 57 Consumer Product Safety 7 Coolant Bottle serere eese 97 Coolant Radiator 98 Cooling System 96 98 Crankcase Emission Control System 83 146 D Demand Drive Fluid 93 Diagnostic Codes 48 50 Dis
5. 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 released This ATV is equipped with a throttle release switch which is designed to reduce the risk of a frozen or stuck throttle If the throttle cable should stick in an open posi tion when the operator releases the throttle lever engine speed will be limited and power to the rear wheels will be reduced 26 FEATURES AND CONTROLS Brake Lever A WARNING Operating the A
6. Polishing Tips Avoid the use of automotive products some of which can scratch the finish of your vehicle Always use clean cloths and pads for cleaning and polishing Old or reused cloths and pads may contain dirt particles that will scratch the finish 125 MAINTENANCE Cleaning and Storage Storage Tips NOTICE Starting the engine during the storage period will disturb the protective film created by fogging and damage could occur Never start the engine during the storage period Clean the Exterior Make any necessary repairs and then clean the vehicle as recommended See page 124 Oil and Filter Change the oil and filter See page 90 Fluid Levels Inspect the following fluid levels Change fluids as recommended in the Periodic Maintenance Chart beginning on page 85 Demand drive unit front gearcase Rear gearcase Transmission 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 instructions on the container for the recom mended 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 126 MAINTENANCE Cl
7. Check for leaks Reinstall the footwell Dispose of used oil properly 9o A ON 92 MAINTENANCE Front Gearcase Demand Drive Fluid Always check and change the demand drive fluid at the intervals out lined in the Periodic Maintenance Chart beginning on page 85 See the table on page 88 for fluid recommendations capacities and plug torques See page 133 for the part numbers of POLARIS products Use the recommended fluid Use of other fluids may result in improper operation of components Maintain the fluid level at the bottom of the fill hole threads The fill plug is located on the right side of the demand drive unit The drain plug is located on the bottom right side of the unit Fluid Check 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 Pra Pl 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 NE US Check for leaks Dispose of used fluid properly 93 MAINTENANCE Rear Gearcase Oil Always check and change the rear gea
8. Clutch Cover Warning WARNING Moving parts hazard under belt clutch guard To prevent serious injury do not operate vehicle with guard removed Do not modify engine or clutch Doing so can cause part failure possible imbalance and excessive engine RPM which can result in serious injury or death 7175488 Rack Warning Front and Rear WARNING DO NOT TOW FROM RACK OR BUMPER Vehicle damage or tipover may result causing severe injury or death Tow only from tow hooks or hitch Max Rack Loads Front 25 Ibs 11 kg Rear 50 Ibs 23 kg 7179093 23 FEATURES AND CONTROLS Switches Mode Reverse Anal l 4X4 Switch Override ngine l Button Stop Switch Main Key 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 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 4X4 or 2X4 See page 32 Headlight Switch Use the headligh
9. Possible Cause Solution Poor quality or low octane fuel Replace with recommended fuel Incorrect ignition timing See your dealer Incorrect spark plug gap or heat range Set gap to specs or replace plugs Engine Runs Irregularly Stalls or Misfires Possible Cause Solution Fouled or defective spark plugs Inspect clean and or replace spark plugs Worn or defective spark plug wires See your 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 battery voltage Recharge battery 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 your dealer Throttle release switch malfunction See your dealer Other mechanical failure See your dealer Possible Lean Fuel Cause Solution Low or contaminated fuel Add or change fuel clean the fuel system Kinked or plugged fuel tank vent line Inspect and replace Low octane fuel Replace with recommended fuel Clogged fuel filter See your dealer Incorrect fuel Replace with recommended fuel Possible Rich Fuel Cause Solution Fuel is very high octane Replace with lower octane fuel Stopping starting without adequate Allow engine to warm up before operat warm up ing a
10. 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 If the 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 Place the transmission in PARK 2 Squeeze and release the brake lever two or three times then squeeze and hold 3 Push the parking brake lock forward to engage the lock 4 Release the brake lever 5 To release the parking brake lock squeeze and release the brake lever It will return to its unlocked position WARNING Operating the ATV while the parking brake is engaged could result in an accident or fire Always check to be sure the parking brake is disengaged before operating The parking brake may relax if left on for a long period of time Always block the wheels to prevent rolling Always block the wheels on the downhill side of the ATV if leaving it parked on a hill Another option is to park the ATV in a sidehill position Never depend on the parking brake alone if the ATV is parked on a hill Always block the wheels to prevent rolling 29 FEATURES AND CONTROLS Auxiliary Foot Brake A WAR
11. Demand Drive 93 Front Rack Compartment 51 Fuel Safety 45 rev eects 11 Fuel Tank Cap seem 31 Fuse Replacement 105 G Gasoline Handling 11 Gauge Code Definitions 48 50 Gauge Digital Analog 34 41 Gauge MFD EPS Models 42 47 Gear Selector vc kt trs 29 Gearcase Oil Rear 94 95 Cllr TTE 9 H Hand Brake 2 eer 99 Handlebar Adjustment 115 Hauling Cargo 68 70 Headlight Switch 24 Helmet ev enc e RET EIS 8 High Beam Adjustment 106 High Range Use 114 l Idle RPM Adjustment 118 Timers e 1 uae etes e Ry 110 Indicator Lamps 35 Instrument Cluster 34 50 K Key SWIC seie esit nma 25 K TUM scu re mn 64 INDEX L Lights esee 106 107 Beam Adjustment EPS 106 Beam Adjustment XP 107 Headlamp Replacement EPS 107 Headlamp Replacement XP 107 Headlight Beam Inspection 106 Taillight Brakelight 107 Low Range Use 114 Lower Headlamp Replacement 107 Lubrication Guide 88 M Maintenance Chart 84 87 Master Cylinder 28 Metric Display 38 45 Mode Switch 05 24 Modifications 005 9 N Noise Emission Control System 83 O Oil Engine ee spese ou sob Lee 4 89 91 Rear Gearcase 94 95
12. Parking on an Incline Avoid parking on an incline if possible If it s unavoidable follow these precautions 1 Stop the engine 2 Place the transmission in PARK 3 Lock the parking brake 4 Always block the rear wheels on the downhill side OPERATION 25 Maximum Ts 63 OPERATION Turning Around on a Hill K Turn If the vehicle stalls while climbing a hill never back it down the hill Use the K turn to turn around 64 Stop and lock the parking brake while keeping body weight uphill Leave the transmission in forward and shut off the engine Dismount on the uphill side of the vehicle or on the left if the vehi cle 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 point ing 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 s owly 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 wa
13. replace the entire taillight assembly 107 MAINTENANCE Spark Plugs Spark Plug Recommendations Refer to the specifications section beginning on page 133 for the recom mended spark plug type and gap for your vehicle Torque spark plugs to specification NOTICE Using non recommended spark plugs can result in serious engine damage Always use POLARIS recommended spark plugs Torque Specification New Spark Plug 18 20 ft Ibs 24 27 Nm Previously Installed Spark Plug 18 20 ft Ibs 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 Immediately check the spark plugs for correct color See page 109 CAUTION A hot exhaust system and engine can cause burns Wear protective gloves when removing a spark plug for inspection 1 Rotate the spark plug cap 1 4 turn and pull it off the spark plug 2 Rotate the spark plug counter clockwise to remove it 3 Reverse the procedure for spark plug installation Torque to specifi cation 108 MAINTENANCE Spark Plugs Spark Plug Inspection Normal Spark Plug The normal insulator tip is gray tan or light brown There will be few combustion deposits The electrodes are not burned or eroded This indi cates the proper type and heat range for the engine and the service The tip should not be flaky and
14. speeds before attempting to turn at faster speeds Jumps and Stunts Attempting wheelies jumps and other stunts increases the risk of an accident or overturn Never attempt wheelies jumps or other stunts Avoid exhibition driving Improper Hill Climbing Improper hill climbing could cause loss of control or overturn Always follow proper procedures for climbing hills as described in the owner s manual See page 61 SAFETY 13 SAFETY Safety Warnings Descending Hills Improperly Improperly descending a hill could cause loss of control or overturn Always follow proper procedures for travel ing down hills as described in the owner s manual NOTE A special technique is required when braking while traveling down hill See page 63 Always descend a hill with the transmission in forward gear Do not descend a hill with the transmission in neutral Always check the terrain carefully before descending a hill Shift your weight rearward Never travel down a hill at high speed Avoid traveling down a hill at an angle which would cause the vehicle to lean sharply to one side Travel straight down the hill when possible Crossing Hillsides Driving on a sidehill is not recommended Improper procedure could cause loss of control or overturn Avoid crossing the side of any hill unless absolutely necessary If crossing a hillside is unavoidable always follow proper procedures as described in th
15. 102 Winch Cable Care 79 Winch Maintenance Service Safety 82 Winch Operation 74 78 Winch Safety Precautions 71 73 Winch Shock Loading 80 81
16. Battery Radiator Cap Electrical Fuse Relay 51 OPERATION Failure to operate the ATV properly can result in a collision loss of control accident or overturn which may result in serious injury or death Read and understand all safety warnings outlined in the safety section of this owner s manual Break In Period The break in period for your new POLARIS ATV is the first 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 52 OPERATION Break In Period 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 89 Add oil if necessary to maintain the level between the safe and add marks 3 Drive slowly at first Select an open area that allows room to famil iarize yourself with vehicle operation and handling 4 Vary the throttle positions Do not operate at sustained idle 5 Perform regular checks on fluid levels controls and areas outlined on the daily pr
17. Follow the battery charging instructions on page 122 before installing the battery If your factory installed 18 AH battery cannot maintain a charge because of operation in extreme cold or with multiple electrical accesso ries please see your POLARIS dealer to purchase a 30 AH battery Before installing the 30 AH battery remove the plastic spacer at the bot tom of the battery compartment Save the spacer for future use 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 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 DICA AD Battery Storage Whenever the vehicle is not used for a period of three months or more remove the battery from the vehicle ensure that it s fully charged and store it out of the sun in a cool dry place Check battery voltage each month during storage and recharge as needed to maintain a full charge POLARIS recommends maintaining battery charge by using a POLARIS 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 d
18. MAINTENANCE Item Maintenance Interval Remarks whichever comes first Hours Calendar Miles Km E Fuel system filter 100 H 12M 1000 1600 Check for leaks at tank cap lines filter pump throttle body replace lines every two years gt Engine mounts 100 H 12M 1000 1600 Inspect Exhaust muffler 100 H 12M 1000 1600 Inspect pipe D Spark 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 100 H 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 36M 3000 4800 Clean out D Valve clearance 1000 H 10000 Inspect adjust as needed E 16000 Toe adjustment Inspect periodically adjust when parts are replaced Headlight aim Adjust as needed 87 MAINTENANCE Lubrication Guide Check and lubricate all components at the intervals outlined in the Peri odic Maintenance Chart beginning on page 85 Items not listed in the chart should be lubricated at the General Lubrication interval The a arms and lower control arms are lubricated at the factory and no additional lubrication will be needed However if these component
19. 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 SCRAMBLER XP 1000 1000 EPS Maximum Towed Load Level Ground 1500 Ibs 680 kg Maximum Vertical Hitch Weight 150 Ibs 68 kg 70 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 rope The term winch cable will be used for either unless noted otherwise Winch Safety Precautions T5099 toe 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
20. POLARIS ATVs the approximate gear ratio difference between high and low range is 1 2 25 This difference in gearing affects the oper ation 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 h the engine would be running at only 1500 RPM Whenever operating this close to the engagement speed the engine may be running at a speed too low to provide the pinch needed to prevent belt slip Belt slip is responsible for creating the excessive heat that destroys belts wears clutch components and causes outer clutch covers to fail The air temperature in the clutch cover is substantially reduced by using low range while operating at low ground speeds Reducing the tempera ture inside the clutch cover greatly extends the life of the PVT compo nents belt cover etc 113 MAINTENANCE PVT System When To Use Low Range and High Range Condition Range to Use Operating at speeds less than 7 MPH 11 km h Low Towing heavy loads Low Operating in rough terrain swamps mountains etc Low Operating at speeds greater than 7 MPH 11 km h High PVT Drying There may be some instances when water is accidently ingested into the PVT system Use the follo
21. Spark Plugs 108 109 Speedometer lusus 34 Starting the Engine 57 Steering Assembly 96 100 StOFage illeseseo hs 124 127 Storage Tips 126 127 148 S Switches 4X4 Switch 00000000 24 32 Engine Stop Switch 25 Headlight Switch 24 Main Key Switch 25 Mode Switch 24 Reverse Override Switch 24 Stop Switch 0 0000 25 T Taillight esses ovre E ERR 107 Throttle Body Adjustment 118 Throttle Cable Freeplay 118 119 Throttle Lever acere RS 26 Tire Tread Depth 102 Tires oosvsserihe e y raais 102 103 Wheel Installation 103 Wheel Nut Torque 103 Wheel Removal 102 Toe Alignment 5 05 0 4 sae enm 100 Towing Capacities 70 Towing Loads suus 70 Trail Etiquette 4 000 0000 56 Wrath vesllevecebetemjeesevs F Transmission Gear Selector 25 Transmission Oil 92 Transporting the ATV 128 Tread Lightly 22i AR 56 Turning Around ona Hill 64 Turning the Vehicle 59 V Vehicle Identification Numbers 6 Vehicle Immersion 110 W Warning Symbols 4 Washing the Vehicle 124 125 Wheel Hub Tightening 102 Wheel Installation 103 Wheel Nut Torque Specifications 103 Wheel Removal
22. by the intake system AII exhaust gases exit through the exhaust system Exhaust Emission Control System Exhaust emissions are controlled by engine design An electronic fuel injection EFI system controls fuel delivery The engine and EFI com ponents are set at the factory for optimal performance and are not adjustable The vehicle compliance labels can be found on the frame tubing of the vehicle Electromagnetic Interference This spark ignition system complies with Canadian 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 83 MAINTENANCE Periodic Maintenance Chart Careful periodic maintenance will help keep your vehicle in safe reli able condition Inspect clean lubricate adjust and replace parts as nec essary When inspection reveals the need for replacement parts use genuine POLARIS parts available from your POLARIS dealer Record maintenance and service in the Maintenance Log beginning on page 144 Service and adjustments are important for proper vehicle operation If you re not familiar with safe service and adjustment procedures ha
23. either 24 hour or 12 hour Release the button 4 New settings remain until changed using the same procedure Odometer Mode The odometer records and displays the distance traveled by the ATV Trip Meter Mode The trip meters record the distance traveled by the ATV on each trip if reset before each trip To reset a trip meter select the trip meter 1 or trip meter 2 mode Press and hold the MODE button on the instrument clus ter until the total changes to 0 In the Rider Information Center the trip meter display contains a decimal point but the odometer displays with out a decimal point Hour Meter Mode This mode logs the total hours the engine has been in operation 45 FEATURES AND CONTROLS Instrument Cluster Multi Function Display MFD Gauge EPS Models 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 pro grammed at 50 hours at the factory Use the following procedure to change the service interval 1 Press the SELECT button until remaining service hours display 2 Press and hold the MODE button 3 When the service hours flash press and release the SELECT button to advance the hours to the desired setting including OFF When the digits stop flashing the inter
24. 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 80 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 71 WINCH GUIDE Winch Safety Precautions 11 12 13 14 15 16 17 18 19 72 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 If winching at an angle is unavoidable follow these precautions A Look at the winch drum occasionally Never let the winch cable stack or accumulate at one end of the winch drum Too much winch cable at one end of the winch drum can damage the winch and the winch cable B If stacking occurs stop winching Follow step 15 on page 78 to feed and rewind the cable evenly b
25. faster speeds WARNING Turning improperly can result in vehicle overturn Never turn abruptly or at sharp angles Never turn at high speeds 59 OPERATION Driving on Slippery Surfaces Sideway Turn in Skid direction of C oec C RA PS EUM S JT Ceu Po O O S BS CC 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 60 OPERATION Driving Uphill 25 Maximum Braking and handling are greatly affected when operating in hilly ter rain Improper procedure could cause loss of control or overturn When ever traveling uphill follow these precautions Dl gs Dn de Us p r2 Drive straight uphill Avoid steep hills 25 maximum Always check the terrain carefully be
26. for scheduled maintenance See page 39 for resetting instructions 4X4 Display This icon displays when the 4X4 system is engaged switch is on 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 vehi cle 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 automati cally 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 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 Repeatthe 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 any tim
27. 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 3100 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 exhaust emissions emission related components include any engine parts related to the following systems Air induction system lgnition system Fuelsystem Exhaust gas recirculation systems The following parts are also consi
28. of winch cable m pom 78 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 Akinked 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 VRALIBIL L HEISE straightened out is shown at B right Even though it may look usable the cable has been permanently and severely damaged It can no longer transmit the load that it could prior to kinking Promptly discontinue use of a winch cable in this condition C Awinch cable made of synthetic rope should be inspected for signs of fraying Replace the cable if fraying is observed shown at right 4 Q Promptly discontinue use of a C 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 wil
29. wheels are spinning This may cause severe drive shaft and clutch damage 7175485 Tire Pressure Load Warning WARNING Improper tire pressure or overloading can cause loss of control Loss of control can result in severe injury or death Cold tire pressure Front 7 0 psi 48 3 kPa Rear 7 0 psi 48 3 kPa Maximum weight capacity 290 Ibs 131 kg Lug nut torque values Steel rims 45 ft lbs 61 Nm Aluminum rims 75 ft lbs 102 Nm 7179107 Reverse Override Warning 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 7175486 21 SAFETY Safety Labels and Locations Discretionary LJ Hitch 7 Warning Capacity Label Discretionary Warning WARNING e Never operate this ATV on HILLS steeper than 25 degrees lt lt 257 To pre vent overturn on hilly terrain use throttle and brakes gradually and shift weight uphill REVERSE operation can be dangerous even at low speeds Steering becomes difficult To prevent loss of control avoid sudden braking or sharp turns 7179079 Hitch Capacity Label TRAILER MAX WEIGHT 1500 LBS 682 KG ON LEVEL GROUND 850 LBS 386 KG UP TO 157 GRADE HITCH MAX VERTICAL WEIGHT 150 LBS 68 KG 7170509 22 SAFETY Safety Labels and Locations Clutch Cover Hack Warning Wenig Warning on clutch box
30. 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 warranty 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 pu
31. ATION 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 SAFETY Safe Riding Gear Always wear appropriate clothing when riding an ATV Wear protective clothing for comfort and to reduce the chance of injury Helmet Eye Protection Long Gloves Sleeves Long Pants Helmet Wearing a helmet can prevent a severe head injury Whenever riding a POLARIS vehicle always wear a helmet that meets or exceeds estab lished safety standards Approved helmets in the USA and Canada bear a U S Department of Transportation DOT label Approved helmets in Europe Asia and Oceania bear the ECE 22 05 label The ECE mark consists Mer of a circle surrounding the letter E followed by the distinguishing number of the country which has granted approval The approval number and serial number will also be displayed on the label SAFETY Safe Riding Gear Eye Protection Do not depend on eyeglasses or sunglasses for eye protection When ever riding a POLARIS vehicle always wear shatterproof goggles or use a shatterproof helmet face shield POLARIS recommends wearing approved Personal Protective Equipment PPE bearing markings such as VESC 8 V 8 Z87 1 or CE Make sure protective eye wear is kept clean Gloves Off road style gloves with knuckle pads are the best for comfort and prote
32. E 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 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 136 WARRANTY LIMITATIONS OF WARRANTIES 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 envir
33. ENANCE Camber and Caster The camber and caster are non adjustable Front Rear Springs XP 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 116 Adjuster MAINTENANCE Front Rear Shock Compression XP EPS The compression damping clicker knob is located on the top of the front shock reservoir and on the bottom of the rear shock reservoir When the knob is turned clockwise until it stops the damping is in the fully closed position FOX Shocks Setting Compression Damping Softest 20 clicks from closed Factory 10 clicks from closed Firmest 2 clicks from closed 1 Turn the clicker clockwise to increase compression damping 2 Turn the clicker counter clockwise to decrease compression damping Decrease Increase ri Increase Decrease 117 MAINTENANCE Throttle Body Idle RPM Idle RPM is preset by the manufacturer If the engine idle speed is not satisfactory please see your POLARIS dealer for adjustment Throttle Cable Freeplay Remove the four cover screws from the right han dlebar control and remove the cover 2 With the handlebars straight ahead place very light pressure on the throt tle lever A gap of 2 3 mm should be visible between the throttle arm stop pin
34. HIS 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 CONSEQUENTAL 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 138 WARRANTY HOW TO OBTAIN WARRANTY SERVICE If your vehicle requires warranty service you must take it to a POLARIS Servicing Dealer When requesting warranty service you must present your copy of the Warranty Registration From to the dealer THE COST OF TRANSPORTATION TO AND FROM THE DEALER IS YOUR RESPONSIBILITY POLARIS suggests that you use your original selling dealer however you may use any POLARIS Servicing Dealer to perform warranty service In the country
35. ING 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 102 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 tighten them 5 Lower the vehicle to the ground 6 Torque the wheel nuts to specification WARNING Loose nuts could cause a tire to come off during operation which could result in an accident or overturn Always ensure that all nuts are torqued to specification 75 ft Ibs 45 ft Ibs 102 Nm 61 Nm Cast Aluminum Steel Wheel Nut Torque Specifications Check the wheel nut torques occasionally and when they ve been loos ened for maintenance service When servicing cast aluminum wheels use either a thin walled impact socket or a standard non impact socket to remove and torque lug nuts Wheel Type Nut Type Nut Torque Aluminum Lug Nut 75 ft Ibs 102 Nm Steel Lug Nut 45 ft lbs 61 Nm 103 MAINTENANCE Air Filter 1 2 104 Remove the seat Remove the air box cover strap and remove the air box cover Remove the filter Remove the fabric type pre fil
36. NCLUDING 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 This limited warranty excludes failures not caused by a defect in material or workmanship This limited warranty does not cover damage due to accidents abuse or improper handling maintenance or use This limited warranty also does not cover any engine that has been structurally altered or when the vehicle has been used in racing competition This limited warranty also does not cover physical damage corrosion or defects caused by fire explosions or other similar causes beyond the control of POLARIS 142 WARRANTY U S A EPA Emissions Limited Warranty 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 responsibility 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 perfo
37. NING 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 If the rear wheels slide while using the auxiliary brake reduce brake pedal pressure to brake the rear wheels without skidding Brake Fluid Level Check the brake fluid level fre quently for the auxiliary brake sys tem The reservoir is located under the front rack Maintain the fluid level between the maximum and minimum marks Use DOT 4 brake fluid only 30 Auxiliary Foot Brake Brake Fluid Reservoir FEATURES AND CONTROLS Fuel Tank Always refuel with the engine Fuel Tank Cap stopped and outdoors or in a well ventilated area Refuel on a level sur face 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 65 fuel The fuel tank is d
38. TV with a spongy brake lever can result in loss of braking which could cause an accident Never operate the ATV with a spongy feeling brake lever Always contact your dealer for service before operating the vehicle Squeeze the brake lever toward the handlebar to apply the front and rear brakes These brakes are hydraulically activated disc type brakes that are activated by only one lever Always test brake lever travel and master cylinder fluid level before riding When squeezed the lever should feel firm Any sponginess would indicate a possible fluid leak or low master cylinder fluid level which must be corrected before riding Contact your dealer for proper diagnosis and repairs 27 FEATURES AND CONTROLS Master Cylinder 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 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 Oylinder Window 1 Position the ATV on a level surface
39. Transmission 00 92 Oil and Filter Change 90 91 Oil Change Rear Gearcase 95 Transmission suse 92 Oil Level Engine iue sends peel atone 89 Rear Gearcase 94 Transmission 0 92 Oil Recommendations 89 Operation on Public Lands 83 Override Switch 24 147 INDEX P Parking Brake 29 Parking on an Incline 63 Periodic Maintenance Chart 84 87 Polaris Product List 133 Polishing the Vehicle 125 Power Steering 31 Power Steering Unit Cleaning 96 Pre Ride Checklist 54 PVT Break In 5 cu trc 53 PVT DEDE crie rines 114 PV I Systems eie 112 114 R Rack Compartment Front 51 Reverse Operation 67 Reverse Override Switch 24 Rider Information Center 36 41 Riding Ar sere 56 Riding Gear 8 9 S Safe Operation Practices 55 Safety Labels oieri essen 20 23 Safety Training 7 Safety Warnings 10 19 Safety Winch Maintenance 82 Severe Use isis cose ees 84 Shock Compression XP EPS 117 Shock Loading the Winch 80 81 Shock Spring Adjustment XP 116 Side Panel Removal 101 Sidehulling ees 62 Signal Words 4 Spark Arrester 111 Spark Plug Inspection 108 109 Spark Plug Recommendations 108
40. V Never operate an ATV without proper instruction Take a training course This vehicle is an ADULT VEHICLE ONLY Operation is prohibited for anyone under 16 years of age Never permit a guest to operate 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 trolled as indicated by the test procedure s The uncertainty of vibration exposure measurement is dependent on many factors including Instrument and calibration uncertainty Variations in the machine such as wear of components Variation of machine operators such as experience or physique Ability of the worker to reproduce typical work during measurements Environmental factors such as ambient noise or temperature INTRODUCTION Vehicle Identification Numbers Record your vehicle s identification numbers and key number in the spaces provided Remove the spare key and store it in a safe place An ignition key can be duplicated only by ordering a POLARIS key blank using your key number and mating it with one of your existing keys The ignition switch must be replaced if all keys are lost Engine Serial Number
41. WELCOME Thank you for purchasing a POLARIS vehicle and welcome to our world wide family of POLARIS enthusiasts Be sure to visit us online at www polaris com for the latest news new product introductions upcoming events career opportunities and more Here at POLARIS we proudly produce an exciting line of utility and recreational products Snowmobiles All terrain vehicles ATVs Low emission vehicles LEVs e RANGERQ utility vehicles e RZRE sport vehicles e VICTORY motorcycles e GEM vehicles We believe POLARIS sets a standard of excellence for all utility and recreational vehicles manufactured in the world today Many years of experience have gone into the engineering design and development of your POLARIS vehicle For safe and enjoyable operation of your vehicle be sure to follow the instructions and recommendations in this owner s manual Your manual contains instructions for minor maintenance but information about major repairs is outlined in the POLARIS Service Manual and should be performed only by a factory certified Master Service Dealer MSD technician Your POLARIS dealer knows your vehicle best and is interested in your total satisfaction Be sure to return to your dealership for all of your service needs during and after the warranty period POLARIS POLARIS and SCRAMBLER are registered trademarks of POLARIS Industries Inc Autolite is a registered trademark of FRAM Group IP LLC Copyr
42. and the lower parts last 2 Rinse with clean water frequently 3 Dry surfaces with a chamois to prevent water spots Washing Tips Avoid the use of harsh cleaners which can scratch the finish Do not use a power washer to clean the vehicle Do not use medium to heavy duty compounds on the finish Always use clean cloths and pads for cleaning and polishing Old or reused cloths and pads may contain dirt particles that will scratch the finish 124 MAINTENANCE Cleaning and Storage Washing the Vehicle If a high pressure water system is used for cleaning not recommended exercise extreme caution The water may damage components and could remove paint and labels Avoid directing the water stream at the follow ing items Wheel bearings Hlectrical components e Radiator Switches and controls Transmission seals Fuel system components Cab and body panels Labels and decals If an informational or graphic label becomes illegible or comes off con tact your POLARIS dealer to purchase a replacement Replacement safety labels are provided by POLARIS at no charge Grease all zerk fittings immediately after washing Allow the engine to run for a while to evaporate any water that may have entered the engine or exhaust system Polishing the Vehicle POLARIS recommends the use of common household aerosol furniture polish for polishing the finish on your POLARIS vehicle Follow the instructions on the container
43. and the throttle arm 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 lock nut 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 adjusting freeplay flip the throttle lever back and forth repeatedly continued on next page 118 2 3 mm Gap Arm Stop Pin Cable Adjuster Boot Lock Nut Adjuster MAINTENANCE Throttle Cable Freeplay 4 2 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 verifying 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 it
44. ate with 10 2 26 cm travel XP Progressive rate with 10 2 26 cm travel XP EPS Rear Suspension 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 75 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 Hi Lo Beam on Bumper 50 watt Taillight Brake Light LED Instrument Cluster Digital Analog XP Digital LCD LED XP EPS Clutching Altitude Shift Drive Driven Helix Weight Clutch Clutch Spring Spring Meters 0 1800 24 70 Red Black Black White 58 66F Feet 0 6000 PN 5633136 Stripe Lettering Parallel BA PN 7043500 PN 7044086 PN 3235590 1800 3700 24 68 Red Black Black White 58 66F 6000 12000 PN 5632418 Stripe Lettering Parallel BA PN 7043500 PN 7044086 PN 3235590 EBS models require no helix spring adjustment 135 WARRANTY LIMITED WARRANTY POLARIS Sales 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 arrest
45. before operating the vehicle 100 MAINTENANCE Seat Removal 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 Rivets Hex Head Screws 101 MAINTENANCE Tires A WARNING Operating your ATV with worn tires improperly inflated tires non standard tires or improperly installed tires will affect vehicle handling and could cause an accident resulting in serious injury or death Always follow all tire maintenance procedures as outlined in this manual and on the labels on the vehicle Always use original equipment size and type when replacing tires Refer to the specifications section beginning on page 133 for recom mended tire type size and pressure Tire Tread Depth f Alwavs replace tires 1 8 3 mm L when tread depth is worn to 1 8 3 mm or less Cp WG Front Wheel Hub Tightening Front wheel bearing tightness and spindle nut retention are critical com ponent operations All service must be performed by your authorized POLARIS dealer Wheel Removal 1 Stop the engine 2 Place the transmission in PARK 3 Lock the parking brake 4 Loosen the wheel nuts slightly WARN
46. ccumulation of contaminates such as water or excess fuel in the bottom of the crankcase Water in the bottom of the crankcase can lead to engine damage and must be drained Water accu mulation increases as outside temperature decreases 57 OPERATION Driving Procedures N po aa Oy en 58 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 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 tech nique alters the balance of trac tion between the rear wheels allowing the turn to be made smoothly The same leaning technique should be used for turning in reverse Practice making turns at slow speeds before attempting to turn at
47. ce 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 91 MAINTENANCE Transmission Oil Always check and change the transmission oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 85 See the table on page 88 for fluid recommendations capacities and plug torques See page 133 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 101 2 Remove the fill plug Check the oil level 3 Add the recommended fluid as needed to bring the level to the e O i bottom of the fill hole threads S YY was OV _ 4 Reinstall the fill plug Torque to specification 5 Reinstall the footwell Drain Plug Oil Change 1 Remove the footwell Fill Plug 2 Place a drain pan under the gearcase Remove the drain plug Allow the oil to drain completely ras 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
48. ceed the stated load capacity for this ATV Cargo should be properly distributed and securely attached Reduce speed when carrying cargo or pulling a trailer Allow a greater dis tance for braking Always follow the instructions in the owner s manual for carrying cargo or pull ing a trailer See pages 68 69 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 headlights frequently and replace burned out headlamps promptly 18 SAFETY Safety Warnings Op
49. cement 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 without proper training or instruction atspeeds too fast for your skills or the conditions on public roads a collision can occur with another vehicle 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 ter rain and in turns avoid paved surfaces pavement may seriously affect handling and control LOCATE AND READ OWNER S MANUAL FOLLOW ALL INSTRUCTIONS AND WARNINGS 7175376 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 20 SAFETY Safety Labels and Locations General Age 16 No Passenger Warning Warning i Tem Warning Reverse Override 4X4 Caution Tire Pressure Load Warning Warning No Passenger Warning WARNING NEVER ride as a passenger Passengers can cause a loss of control resulting in SEVERE INJURY or DEATH 7175378 4X4 Caution CAUTION Do not push switch to engage 4X4 AWD if the rear
50. ction Boots The best footwear is a pair of sturdy over the calf boots with low heels Clothing Always wear long sleeves and long pants to protect arms and legs Rid ing pants with kneepads and a jersey with shoulder pads provide the best protection Equipment Modifications We strongly recommend that consumers do not install on a POLARIS ATV any equipment that may increase the speed or power of the vehicle or make any other modifications to the vehicle for these purposes The warranty on your POLARIS ATV is terminated if any equipment has been added to the vehicle or if any modifications have been made to the vehicle that increase its speed or power The addition of certain accessories including but not limited to mow ers blades tires sprayers or large racks may change the handling char acteristics of the vehicle Use only POLARIS approved accessories and familiarize yourself with their function and effect on the vehicle SAFETY Safety 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
51. dered emission related components for exhaust emissions Aftertreatment devices Sensors Crankcase ventilation valves Electronic control units 141 WARRANTY U S A EPA Emissions Limited Warranty 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 Liquid Vapor Separator Carbon Canister Canister Mounting Brackets Carburetor Purge Port Connector o o o o o o e o o o o As related to the evaporative emission control system 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 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 I
52. e 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 jp E m mu mo mo mu mu JI Ii NAI ir Trip 1 RPM NA NANA NAAN INI IAN AN TAN N VANTIN 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 Clock Display The clock displays time in a 12 hour or 24 hour format If the engine is turned off press the MODE button The time will display for 5 10 seconds See page 39 for resetting instruc tions Service Reminder Display A flashing wrench symbol alerts the operator that the preset service interval has been reached The vehi cle should be brought to your dealer
53. e 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 140 WARRANTY U S A EPA Emissions Limited Warranty This emissions limited warranty is in addition to the POLARIS standard limited warranty for your 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 Agency 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 or 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
54. e owner s manual See page 62 Never attempt to turn the ATV around on any hill until you ve mastered the turning technique on level ground as described in the owner s manual See page 64 14 SAFETY Safety Warnings Stalling While Climbing a Hill Stalling rolling backwards or improperly dismounting while climbing a hill could cause an overturn Always maintain a steady speed when climbing a hill If all forward speed is lost Keep body weight uphill Apply the brakes Lock the parking brake when fully stopped Dismount on uphill side or to either side if ATV is pointed straight uphill Turn the ATV around and remount following the procedure described in the owner s manual See page 64 If the ATV begins rolling downhill Keep body weight uphill Never apply engine power Never apply the rear brake while rolling backwards Apply the single lever brake gradually When fully stopped apply the rear brake as well and then lock the parking brake Dismount on uphill side or to either side if ATV is pointed straight uphill Turn the ATV around and remount following the procedure described in the owner s manual See page 64 Operating on Steep Hills Operating on excessively steep hills could cause an overturn Never operate on hills too steep for the ATV or for your abilities Never operate the ATV on hills steeper than 25 degrees 15 Safety Warnings Operating in Un
55. e ride inspection checklist See page 54 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 thereafter PVT Break in Clutches Belt A proper break in of the clutches and drive belt will ensure a longer life and better performance Break in the clutches and belt by operating at slower speeds during the break in period as recommended Pull only light loads Avoid aggressive acceleration and high speed operation dur ing the break in period If a belt fails always clean away all debris when replacing the belt 53 OPERATION Pre Ride Checklist Failure to inspect and verify that the ATV is in safe operating condition before operating increases the risk of an accident Always inspect the ATV before each use to make sure it s in safe operating condition Item Remarks Page Brake system lever travel Ensure proper operation A Brake fluid Ensure proper level 28 Auxiliary brake Ensure proper operation 30 Front suspension Inspect lubricate if necessary 88 Rear suspension Inspect lubricate if necessary 88 Steering Ensure free operation Tires Inspect condition and pressure 102 Wheels fasteners Inspect ensure fastener tightness 10d Frame nuts bolts fasteners Inspect ensure tightness Fuel and oil Ensure proper levels 2 Coolant leve
56. e the battery has been disconnected or dis charged 1 Turn the key to the ON position Use the MODE button to toggle to the odometer display 2 Press and hold the MODE button until the hour segment flashes Release the button 3 With the segment flashing tap the MODE button to advance to the desired setting 4 Press and hold the MODE button until the next segment flashes Release the button 5 Repeat steps 3 4 twice to set the 10 minute and 1 minute segments After completing the 1 minute segment step 4 will save the new settings and exit the clock mode 6 Turn the key to the OFF position Odometer Mode The odometer records and displays the distance traveled by the ATV Trip Meter Mode The trip meter records the distance traveled by the ATV if reset before each trip 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 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 remi
57. eaning and Storage Storage Tips Fog the Engine 1 After stabilizing the fuel remove the spark plugs and add 2 3 table spoons 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 mea sured amount of oil 2 Reinstall the spark plugs Torque to specification 3 Apply dielectric grease to the inside of each spark plug cap and rein stall 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 cyl inder 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 104 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 85 Battery Maintenance Remove the battery and recharge it as outlined on page 122 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 co
58. 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 114 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 freezing Wrong or missing belt Install the recommended belt Improper break in Always break in a new belt and or clutch See page 53 129 TROUBLESHOOTING Engine Doesn t Turn Over Possible Cause Low batterv voltage Solution Recharge the batterv to 12 8 VDC Loose batterv connec
59. ed 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 82 EMISSION CONTROL SYSTEMS Noise Emission Control System Do not modify the engine intake or exhaust components as doing so may affect compliance with U S A EPA noise control requirements 40 CFR 205 and local noise level requirements Operation on Public Lands in the U S A Your POLARIS vehicle has a spark arrester that was tested and qualified to be in accordance with the USFS standard 5100 1c Federal law requires that this spark arrester be installed and functional when the vehicle is operated on public lands Operation of off road vehicles on public lands in the U S A is regulated by 43 CFR 420 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
60. efore continuing the winch operation Never winch up or down at sharp angles This can destabilize the winching vehicle and possibly cause it to move without warning Never attempt to winch loads that weigh more than the winch s rated capacity 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 Never touch push pull or straddle the winch cable while winching a load Never let the winch cable run through your hands even if wearing heavy gloves Never release the clutch on the winch WA when the winch cable is under load Never use the winch for lifting or transporting people WINCH GUIDE Winch Safety 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 cable 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 T3 WINCH GUIDE Winch Operat
61. endations for ambient temper ature operation See page 133 for the part numbers of POLARIS prod ucts See the table on page 88 for fluid recommendations capacities and plug torques 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 Cil Level Check the oil level when the engine is cold Never check the oil with the engine running Position the vehicle on a level surface 2 Access the oil dipstick and fill tube from the left side of peuo the ATV Remove the dip stick Wipe it dry with a clean cloth Full Pis 3 Reinstall and tighten the dip stoke s OG a 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 dipstick maa S 89 MAINTENANCE Engine Oil Oil and Filter Change See the table on page 88 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 85 Always change the oil filter whenever changing oil Oil Filter Top View Access Drain i 7 Guard Plate 1 Position the vehicle on a level surface 2 Start the engine Allow it to warm up at idle for two to three min utes 3 Stop
62. ensor T2 Par T2 Shorted to Ground 520224 4 ali T2 Shorted to Bus 520224 3 Steering Torque Sensor Full T1 and T2 Shorted to Ground 520225 4 Kalue T1 and T2 Shorted to Bus 520225 3 T1 Short to Ground amp T2 Short to Bus 520225 16 T2 Short to Ground amp T1 Short to Bus 520225 17 T1 and T2 are Shorted 520225 2 Steering Position Sensor P1 P1 Shorted to Ground 520226 4 Pana kalur P1 Shorted to Bus 520226 3 Steering Position Sensor P2 P2 Shorted to Ground 520227 4 parti tali P2 Shorted to Bus 520227 3 Steering Position Sensor Full P1 and P2 Shorted to Ground 520228 4 Palle P1 and P2 Shorted to bus 520228 3 EPAS Inverter Temperature Greater than 110 Degrees C 520229 16 Greater than 120 Degrees C 520229 0 EPAS CAN Comm Receive Err No RX Message for 2 Seconds 520230 9 EPAS CAN Comm Transmit Err No TX Message for 2 Seconds 520231 9 IC CAN Comm w EPAS EPAS Offline 520230 31 50 FEATURES AND CONTROLS Front Rack Compartment Release the front rack latches Latches and remove the rack to gain access to the front compart ment 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 Access the following components in the front compartment Radiator cap Brake fluid reservoir Battery Coolant recovery bottle cap Electrical fuse relay components Brake Fluid Coolant Bottle Cap Reservoir
63. equires no adjustment Check the brake fluid level frequently for the auxiliary brake system See page 30 99 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 Position the vehicle on a level surface 2 Placethe handlebars ina Stand straight ahead position 3 Tie a length of string between two stands as shown in the illustration Position the stands so that the string is flush with the side of the rear tire If available you may use a long straight edge instead of string 2 l TU 4 Measure the distance from the string to the rim at the front 1 and rear 2 of the front rim The rear measurement should be 1 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 String 5 Repeat the measurement procedure on the other side of the vehicle 6 If you 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
64. erating a Damaged ATV Operating a damaged ATV can result in an accident After any overturn or accident have a qualified service dealer inspect the entire machine for possible damage including but not limited to brakes throttle and steering systems Physical Skills Safe operation of this rider active vehicle requires good judgement and physical skills Persons with cognitive or physical disabilities who operate this vehicle have an increased risk of overturn and loss of control 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 SAFETY Safety Labels and Locations Warning labels have been placed on the vehicle for your protection Read and follow the instructions on each label carefully If any of the labels shown in this manual differ from the labels on your vehicle always read and follow the instructions of the labels on the vehicle If an informational or graphic label becomes illegible or comes off con tact your POLARIS dealer to purchase a repla
65. erturn Before operating in a new area check for obstacles Avoid operating over large obstacles such as rocks and fallen trees If unavoidable use extreme caution and always follow proper operating procedures as outlined in this manual See page 66 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 65 Travel slowly Balance your weight carefully Avoid sudden movements Maintain a slow and steady forward motion Do not make sudden turns or stops and do not make sudden throttle changes Wet brakes may have reduced stopping ability After leaving water test the brakes Apply them lightly several times while driving slowly The friction will help dry out the pads 17 SAFETY Safety Warnings Improper Cargo Loading Overloading the ATV or carrying towing cargo improperly may cause changes in handling which could cause loss of control or an accident Never ex
66. esigned to allow for the normal expansion of fuel Do not overfill Do not fill the tank neck Extreme Use 30 AH Battery If your factory installed 18 AH battery cannot maintain a charge because of operation in extreme cold or with multiple electrical accesso ries please see your POLARIS dealer to purchase a 30 AH battery 1 Fully charge the new battery before installing it See page 122 2 Toinstall the 30 AH battery remove the 18 AH battery See page 120 3 Remove the plastic spacer at the bottom of the battery compartment Save the spacer for future use 4 Install the new battery See page 121 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 43 for EPS Warning Indicator information 31 FEATURES AND CONTROLS All Wheel Drive System The AII Wheel Drive system is controlled by the 4X4 switch 4X4 Mode When the switch is on 4X4 the ATV is in 4X4 and the 4X4 indi cator icon in the instrument clus ter 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
67. familiar Terrain Failure to use extra caution when operating on unfamiliar terrain could result in an accident or overturn Unfamiliar terrain may contain hidden rocks bumps or holes that could cause loss of control or overturn Travel slowly and use extra caution when operating on unfamiliar terrain Always be alert to changing terrain conditions Operating on Slippery Terrain Failure to use extra caution when operating on excessively rough slippery or loose terrain could cause loss of traction loss of control accident or overturn Do not operate on excessively rough slippery or loose terrain Always use extra caution on rough slippery or loose terrain Operating 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 67 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 SAFETY Safety Warnings Operating Over Obstacles Improperly operating over obstacles could cause loss of control or ov
68. fore 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 rate 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 61 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 62 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 Driving Downhill When driving downhill follow these precautions 1 Avoid steep hills 25 maximum 2 Shift body weight uphill 3 Drive straight downhill 4 Slow down Excessive speed when traveling down hill can cause loss of con trol 5 Squeeze the brake lever gradually Applying the brakes too firmly may cause the rear wheels to lock which could result in loss of control
69. gnostic 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 48 FEATURES AND CONTROLS Instrument Cluster Diagnostic Display Code Definitions SCRAMBLER XP 1000 1000 EPS Diagnostic Codes Component Condition SPN FMI Injector 2 PTO SDI Part Load Driver Circuit Open Grounded 652 5 Driver Circuit Short to B 652 3 Driver Circuit Grounded 652 4 Ignition Coil Primary Driver 1 Driver Circuit Short to B 1268 3 MAG Ignition Coil Primary Driver 2 Driver Circuit Short to B 1269 3 PTO Fuel Pump Driver Circuit Driver Circuit Open Grounded 1347 5 Driver Circu
70. heel well Access the recovery bottle cap under the front storage com partment 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 Coolant Bottle Cap Maximum Mark um 97 MAINTENANCE Cooling System Radiator Coolant To ensure that the coolant maintains its ability to protect the engine POLARIS recommends that you drain the system completely every two years and add a fresh mixture of antifreeze and water Replace the coolant any time the cooling system has been drained for maintenance or repair If the recovery bottle has run dry check the level in the radiator Add coolant as needed CAUTION Escaping steam can cause burns Never remove the pressure cap while the engine is warm or hot Always allow the engine to cool before removing the pressure cap 1 Remove the front rack 2 Remove the pressure cap 3 Using a funnel slowly add cool ant through the radiator filler neck 4 Reinstall the pressure cap Use of a non standard pressure cap will not allow the recovery system to function properly Contact your dealer for the correct replacement part Radiator 5 Reinstall the front rack Cap 98 MAINTENANCE Brakes Hand Brake The front and rear brakes are
71. his warning can result in severe injury or death Do not modify any component of the PVT system Doing so may reduce its strength so that a failure may occur at a high speed The PVT system has been precision balanced Any modification will cause the system to be out of balance creating vibration and additional loads on components The PVT system rotates at high speeds creating large amounts of force on clutch components Extensive engineering and testing has been conducted to ensure the safety of this product However as the owner you have the following responsibilities to make sure this system remains safe Always follow all recommended maintenance procedures Always look for and remove debris inside and around the clutch and vent system when replacing the belt See your dealer as outlined in the owner s manual This PVT system is intended for use on POLARIS products only Do not install itin any other product Always make sure the PVT housing is securely in place during operation 112 MAINTENANCE PVT System The basic operation of the POLARIS PVT system is dependent on engine speed and vehicle torque requirements As engine speed increases the force exerted on the movable drive sheave by the fly weights 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
72. hydraulic disc brakes activated by moving the single brake lever toward the handlebar These brakes are self adjusting Under normal operation the diaphragm extends into the reservoir as fluid level drops If the fluid level is low and the diaphragm is not extended a leak is likely and the diaphragm should be replaced To ensure proper diaphragm operation always fill the reservoir as needed whenever the cover is loosened or removed Do not overfill WARNING An over full master cylinder may cause brake drag or brake lock up which could result in serious injury or death Maintain brake fluid at the recommended level Do not overfill The following checks are recommended to keep the brake system in good operating condition Check more often if brakes are used heavily under normal operation 1 Always keep brake fluid at an adequate level See page 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 3 64 1 mm 5 Check the security and surface condition 3 64 1 mm of the disc Clean any grease using a rec ommended 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 r
73. ide button also acts as a MODE button when held down for approximately one half MODE SELECT second The reverse override but Button Button ton also acts as the SELECT but ton when pressed and released quickly The transmission cannot be in reverse when using the override but ton as a MODE or SELECT button This feature does not contain a vehicle speed lockout function and can be used at any operating speed Speed Display Use the MODE button to toggle through the speed display options Ground speed is displayed in either miles per hour MPH or kilometers per hour km h Engine speed is displayed in revolutions per minute RPM 44 FEATURES AND CONTROLS Instrument Cluster Multi Function Display MFD Gauge EPS Models Display Units Standard Metric The display can be viewed in either standard or metric units of measure ment To change units 1 Press and hold the MODE button until vehicle speed is displayed 2 Toggle through the information area using the SELECT button until the odometer is displayed 3 Press and hold the MODE button until the displayed units change Release the button 4 New settings remain until changed using the same procedure 12 Hour 24 Hour Clock Display 1 Press and hold the MODE button until RPM is displayed 2 Toggle through the information area using the SELECT button until the odometer is displayed 3 Press and hold the MODE button until the clock displays the new clock format
74. ides Stability and maneuverability may be adversely affected causing the vehicle to overturn DO NOT BLOCK THE FRONT HEADLIGHT BEAM when carrying loads on the front rack DO NOT TRAVEL FASTER THAN THE RECOMMENDED SPEEDS 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 68 OPERATION 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 sta ble driving conditions Do not obstruct the headlight beam with cargo Use low forward gear when hauling or towing heavy cargo to extend belt life 69 OPERATION Hauling Cargo Towing Loads Always attach a towed load to the hitch point Remove the hitch from the ATV when not towing a trailer If towing a load reduce rear rack cargo weight by the amount of tongue weight The combination of rear rack cargo weight and tongue weight must not exceed the rear rack capacity The total load operator accessories cargo and weight on hitch must not exceed the maximum weight capacity of the vehicle
75. ight 2013 POLARIS Sales Inc All information contained within this publication is based on the latest product information at the time of publication Due to constant improvements in the design and quality of production components some minor discrep ancies may result between the actual vehicle and the information presented in this publi cation Depictions and or procedures in this publication are intended for reference use only No liability can be accepted for omissions or inaccuracies Any reprinting or reuse of the depictions and or procedures contained within whether whole or in part is expressly prohibited The original instructions for this vehicle are in English Other languages are provided as translations of the original instructions Printed in U S A 2014 SCRAMBLER XP 1000 SCRAMBLER XP 1000 EPS Owner s Manual P N 9924627 TABLE OF CONTENTS IntrodUcllOn sscunse e REREERRRERERRRER EE 4 Safety v Pm 7 Features and Controls 24 Operation cox ER ER EEEE TT RERES 52 Winch GHWldesi ceskerIcE 9 EST dad wa ee ett 71 Emission Control Systems 83 Maintenance ss ss 84 Troubleshooting cece ee eens 129 POLARIS Products 133 Specifications eeee 134 Warranty coe acRRERRE ER ISERECEERERAERA 136 Maintenance Log 144 ipis PM E E E EE 146 INTRODUCTION The following signal words and s
76. ill the tank Do not fill the tank neck f gasoline spills on your skin or clothing immediately wash it off with soap and water and change clothing Exposure to Exhaust Engine exhaust fumes are poisonous and can cause loss of consciousness or death in a short time Never start the engine or let it run in an enclosed area The engine exhaust from this product contains chemicals known to cause cancer birth defects or other reproductive harm Operate this vehicle only outdoors or in well ventilated areas 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 SAFETY Safety Warnings Carrying 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 o
77. ing cargo REDUCE SPEED AND ALLOW GREATER DISTANCES FOR BRAKING WHEN HAULING CARGO NEVER EXCEED THE MAXIMUM WEIGHT CAPACITY of the vehicle When determining the weight you are adding to the vehicle include the weight of the operator 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 s
78. ion Read the Winch Safety Precautions in the preceding pages before using your winch Tip Consider practicing the operation and use of your winch before you actually need to use it in the field 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 74 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 Always inspect the vehicle winch winch cable and winch controls for any signs of damage or parts in need of repair or replacement before each use Pay particular attention to the first 3 feet 1 meter of winch cable if the winch is being used or has been used for lift ing an accessory plow assembly Promptly replace any worn or damaged cable Never operate a winch or a vehicle in need of repair or service Always apply your vehicle s park brake and or park mechanism to hold the vehicle in place during winching Use wheel chocks if needed Hook Strap A AP Ca WINCH GUIDE Winch Operation 4 A
79. it 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 Idle Speed Speed Too High 520211 3 Speed Too Low 520211 4 49 FEATURES AND CONTROLS Instrument Cluster Diagnostic Display Code Definitions SCRAMBLER XP 1000 EPS Diagnostic Codes EPS Models Only Steering Over Current Shutdown Current Above Normal Grounded 520221 6 Steering Excessive Current Error Current Above Normal Grounded 520222 6 Steering Torque Sensor T1 Par T1 Shorted to Ground 520223 4 sina T1 Shorted to Bus 520223 3 Steering Torque S
80. l 25H 1M 250 400 Break in oil level check b Transmission oil 25 H 1M 250 400 JBreak in oil level check gt General 50 H 3M 500 800 Lubricate all fittings pivots lubrication cables etc Shift linkage 50 H 6M 500 800 jInspect lubricate D Steering 50H 6M 500 800 JLubricate b Front suspension 50 H 6M 500 800 JLubricate b Rear suspension 50 H 6M 500 800 Lubricate E Throttle cable 50 H 6M 500 800 Inspect adjust lubricate release switch replace if necessary E Throttle body 50 H 6M 500 800 Inspect duct for proper intake ducts flange sealing air leaks Drive belt 50 H 6M 500 800 Inspect adjust replace as needed Cooling system 50 H 6M 1000 1600 Inspect coolant strength seasonally pressure test system yearly b Radiator 50 H 6M 1000 1600 Inspect clean external surfaces gt Cooling hoses 50 H 6M 1000 1600 Inspect for leaks gt Oil lines and 100 H 6M 1000 1600 Inspect for leaks and loose fasteners fittings gt Engine oil change 100 H 6M 1000 1600 Change the oil and filter gt Demand drive fluid 100 H 12M 1000 1600 Change fluid normal use gt Rear gearcase oil 100 H 12M 1000 1600 Change fluid b 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 86 Periodic Maintenance Chart
81. l Ensure proper level A Coolant hoses Inspect for leaks Throttle Ensure proper operation ia Indicator lights switches Ensure operation 24 Engine stop switch Ensure proper operation 25 Air filter pre filter Inspect clean 104 Headlamp Check operation 24 106 Brake light tail lamp Check operation 107 Riding gear Wear approved helmet goggles and 8 protective clothing 54 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 oper ate 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 emer gency 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 fre quently and replace burned out headlamps promptly Drive in a manner appropriate for your skills and operating condi tions Never operate at excessive speeds Never attempt wheelies jumps or other stunts Never rem
82. l be stiff and appear smooth or glazed Promptly discontinue use of a winch cable in this condition 79 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 80 Never quickly turn the winch ON and OFF repeatedly jogging This puts extra load on the winch winch cable and generates excessive heat from the motor This is a form of shock loading 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 po
83. lways use the hook strap when handling the hook WARNING Never put your fingers into the hook This could lead to SEVERE INJURY NO YES A Attach the hook itself onto the load or use a tow strap or chain to secure the load to the winch cable Tip A tow strap is NOT intended to stretch A recovery strap is designed to stretch WARNING Never use a recovery strap when winching due to the excessive energy that can be released if the winch cable breaks This can result in SEVERE INJURY or DEATH See the Shock Loading section on page 80 B Never hook the winch cable back onto itself This will damage the winch cable and may result in winch cable failure WARNING Replace the winch cable at the first sign of damage to prevent SEVERE INJURY or DEATH in the event of failure For your safety always replace POLARIS winch parts including the cable with genuine POLARIS replacement parts available at your authorized POLARIS dealer C If possible keep the winch cable aligned with the centerline of the winching vehicle This will help the spooling of the winch cable and reduce the load on the fairlead D If freeing a stuck vehicle by attaching to a tree use an item such as a tow strap to avoid damaging the tree during winch operation Sharp cables and chains can damage and even kill trees Please remember to TreadLightly treadlightly org E Before operating the winch be sure that the safety latch on the winch cable hook i
84. mbly 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 temperature increases the expanding heated excess coolant is forced out of the engine past the pressure cap and into the recovery bottle As engine coolant temperature decreases the con tracting cooled coolant is drawn back up from the bottle past the pres sure cap and into the radiator Some coolant level drop on new vehicles is normal as the system is purging itself of trapped air Check the coolant level and maintain as recommended by adding coolant to the recovery bottle POLARIS recommends the use of POLARIS Antifreeze 60 40 premix or a 50 50 mixture of high quality aluminum compatible anti freeze coolant and distilled water POLARIS Antifreeze is already premixed and ready to use Do not dilute with water See page 133 for the part numbers of POLARIS products Always follow the manufacturer s mixing recommendations for the freeze protection required in your area 96 MAINTENANCE Cooling System Recovery Bottle Coolant The recovery bottle fluid level can be viewed from inside the front right w
85. nated trails Trail Etiquette Always practice good etiquette when riding Allow a safe distance between your vehicle and other vehicles operating in the same area Communicate to oncoming operators by signaling the number of vehi cles in your group When stopping move your vehicle to the edge of the trail as far as possible to allow others to pass safely 56 OPERATION Starting the Engine Position the vehicle on a level surface outdoors or in a well venti lated 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 key past the ON position to engage the starter Activate the starter for a maximum of five seconds releasing the key when the engine starts If the engine does not start return the key to the OFF position and wait five seconds before attempting to start again Activate the starter for another five seconds if necessary Repeat this procedure until the engine starts NOTICE Operating the vehicle immediately after starting could cause engine damage Allow the engine to warm up for several minutes before operating the vehicle Cold Weather Operation If the ATV is used year round check the oil level frequently A rising oil level could indicate the a
86. nd or stopping Incorrect fuel Replace with recommended fuel Clogged air filter Inspect and clean or replace 131 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 Throttle release switch 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 Debris lodged in screen Clean the screen Plugged Radiator Use a garden hose to flush any debris from the radiator fins NOTE High pres sure washers can deform the radiator fins and reduce cooling efficiency 132 POLARIS PRODUCTS
87. ndensa tion and may promote corrosion and oxidation 127 MAINTENANCE Transporting the ATV l Stop the engine Place the transmission in PARK Lock the parking brake Secure the fuel cap oil cap and seat t ec b Always tie the frame of the ATV to the transporting unit securely with suitable straps or rope Do not attach tie straps to the front A arm bolt pockets racks or handlebars 6 Remove the key to prevent loss during transporting Accessories Auxiliary power outlets provide 12 volt power for operating accesso ries Accessory outlets are available for all models POLARIS also has a wide range of additional accessories available for your ATV Always install accessories that are approved for ATV use Please see your POLARIS dealer 128 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 64 Driving at low RPM or ground speed 3 7 MPH Drive at a higher speed or use low range more frequently See page 114 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
88. nder to perform routine maintenance The service interval is pro grammed at 50 hours at the factory Use the following procedure to change the service interval 1 Press the MODE button until remaining service hours display 2 Press and hold the MODE button 3 When the service hours flash press and release the MODE button to advance the hours to the desired setting including OFF Press and hold the MODE button to set the new service hour interval Diagnostic Display Mode The EFI diagnostic display mode is for informational purposes only Please see your POLARIS dealer for all major repairs The diagnostic mode is accessible only when the check engine warning indicator activates after the key has been turned on Leave the key on if you want to view the active code failure code The diagnostic mode becomes inaccessible if the key is turned off and on and the warning indicator is no longer active This allows the deter mination of persistent as well as intermittent faults Inactive codes are stored in the history of the unit 40 FEATURES AND CONTROLS Instrument Cluster Digital Analog Gauge Rider Information Center Engine Error Codes The error screen displays only when the CHECK ENGINE light is on or when it goes on and off during one ignition cycle Error codes are not stored in the gauge when the key is turned off The code and message is lost but will reappear if the fault reoccurs after restart ing the engi
89. ne If the CHECK ENGINE light illuminates retrieve the error codes from the dis play Please see your Suspect Parameter Number SPN Error Code Number 0 9 Failure Mode Indicator FMI POLARIS dealer for all major repairs 1 If the error codes are not displayed use the MODE button to toggle until Ck ENG displays on the main line of the display 2 Press and hold the MODE button to enter the diagnostics code menu 3 Record the numbers displayed in the gear position if any clock and odometer displays 4 Press the MODE button to advance to the next error code p Press and hold the MODE button to exit the diagnostics code menu 6 See pages 48 50 for code definitions and failure descriptions Please see your POLARIS dealer for all major repairs 41 FEATURES AND CONTROLS Instrument Cluster Multi Function Display MFD Gauge EPS Models The rider information center is located in the instrument cluster All segments will light up SBE A x for one second at start up If the instrument cluster fails to illuminate a battery over volt ge age may have occurred and the cluster may B za Um have shut down to protect the electronic speed LOO ometer 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
90. ng a constant current charger use the guidelines on the next page for recharging 122 MAINTENANCE Battery Battery Charging Always verify battery condition before and 1 2 hours after the end of charging State of Charge Time 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 5 11 hours 50 75 12 0 12 5 volts Needs charge 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 123 MAINTENANCE Cleaning and Storage Washing the Vehicle Keeping your POLARIS vehicle clean will not only improve its appear ance but it can also extend the life of various components NOTICE High water pressure may damage components POLARIS recommends washing the vehicle by hand or with a garden hose using mild soap Certain products including insect repellents and chemicals will damage plastic surfaces Do not allow these types of products to contact the vehicle The best and safest way to clean your POLARIS vehicle is with a gar den hose and a pail of mild soap and water 1 Usea professional type washing cloth cleaning the upper body first
91. nly 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 77 WINCH GUIDE Winch Operation 13 Extensive winching will run down the battery on the winching vehicle Let the winching vehicle s engine run while operating the winch to prevent the battery from running low if winching for long periods 14 The winch motor may become hot during winch use If you winch for more than 45 seconds or if the winch stalls during operation stop winching and permit the winch to cool down for 10 minutes before using it again 15 After winching is complete especially if winching at an angle it may be necessary to re distribute the winch cable across the winch drum You will need an assistant to perform this task Release the clutch on the winch Feed 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
92. onmental 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 e o e o o o ee o o Batteries Electronic components Light bulbs Sealed beam lamps Spark plugs Filter 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 137 WARRANTY LIMITATIONS OF WARRANTIES AND REMEDIES THE EXCLUSIVE REMEDY FOR BREACH 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 T
93. ons when operating over obstacles 1 Always check for obstacles before operating in a new area 2 Look ahead and learn to read the terrain Be constantly alert for haz ards such as logs rocks and low hanging branches 3 Travel slowly and use extra caution when operating on unfamiliar terrain Not all obstacles are immediately visible 4 Never attempt to operate over large obstacles such as rocks or fallen trees 66 OPERATION Driving in Reverse Follow these precautions when operating in reverse D gs d ey or 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 67 OPERATION Hauling Cargo A WARNING Overloading the vehicle or carrying or towing cargo improperly can alter vehicle handling and may cause loss of control or brake instability which can result in serious injury or death Always follow these precautions when haul
94. or 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 POLARIS 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 COVERAG
95. or not If water has been ingested into the PVT follow the procedure on page 114 for drying out the PVT 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 If your model is equipped with dual exhaust periodically perform the following procedure for both arresters to remove accumulated carbon 1 Remove the retaining nut Remove the arrester from the end of the muffler 2 Use a non svnthetic brush to clean the arrester screen A synthetic brush may melt if components are warm If necessary blow debris from the screen with compressed air 3 Inspect the screen for wear and damage Replace a worn or damaged screen 4 Reinstall the arrester Torque the nut to 7 9 ft Ibs 10 12 Nm Arrester Wars x ae er PE Poeni U LI PRA T sped rd Muffler 111 MAINTENANCE PVT System A WARNING Failure to comply with the instructions in t
96. or 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 Headlight Beam Adjustment XP EPS The headlight beam can be adjusted horizontally and vertically Tighten or loosen the one or more of the three headlight adjustment screws to adjust the beam upward or downward or to the left or right Screws 106 MAINTENANCE Lights Headlight Beam Adjustment XP The headlight beam can be adjusted verti cally Phillips Screw 1 Loosen the phillips screw located at the rear of the headlamp 2 Tilt the headlamp upward or down ward 3 Tighten the screw Headlamp Replacement XP Turn the back of the headlight harness counter clockwise and pull the harness assembly away from the headlight assembly 2 Remove the headlamp and install the new headlamp 3 Reinstall the harness assembly into the headlight assembly 4 Turn the headlight harness clockwise to secure the head lamp Headlamp Replacement XP EPS If a headlight becomes damaged or inoperable the entire headlight assembly must be replaced Taillight Brakelight Lamp Replacement The taillight assembly is not serviceable If the light fails to operate properly
97. ove your hands from the handle bars 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 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 com bustible materials away from the exhaust system Always remove the ignition key when the vehicle is not in use to prevent unauthorized use 55 OPERATION Know Your Riding Area Tread Lightly Familiarize yourself with all laws and regulations concerning the opera tion of this off road vehicle in your area Respect the environment in which you ride Find out where the designated riding areas are by con tacting your POLARIS dealer a local riding club or local officials Help keep our trails open for recreational vehicle use As an off road enthusiast you represent the sport and can set a good example or a poor example for others to follow Tread lightly Operate with respect for the terrain avoid littering and always stay on the desig
98. page 45 Is 42 Gear Display This area displays gear shifter posi tion H High Gear L Low Gear N Neutral R Reverse Gear P Park Gear Signal Error or shifter between gears Information Display This area displays odometer tripmeters engine hour meter and programmable service hour interval Speed Display This area displays vehicle ground speed or engine speed See page 44 FEATURES AND CONTROLS Instrument Cluster Multi Function Display MFD Gauge EPS Models 4 Tip 10 11 12 13 Fuel Gauge The segments of the fuel gauge show the level of fuel in the fuel tank When the last segment clears a low fuel warning is activated All segments 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 High Beam Indicator This indicator illuminates when the lights are set to high beam Engine Overheat Warning This icon flashes to indicate an over heated engine If the icon stops flashing but remains illuminated the overheating condition remains and the system will automati cally reduce engine power Clock Display The clock displays time in a 12 hour or 24 hour format If the engine is turned off press the MODE button The time will display for 5 10 seconds See page 46 for resetting instruc tions Service Reminder Display A flashing wrench
99. per hour MPH or kilometers per hour km h Indicator Lamps Speedometer j Rider Information Center 34 FEATURES AND CONTROLS Instrument Cluster Digital Analog Gauge Indicator Lamps Lamp Indicates Condition When standard mode is selected speed displays in Vehicle miles per hour Speed z When metric mode is selected speed displays in kilometers per hour E Over This lamp flashes to indicate an overheated engine If ee Temperature the indicator stops flashing but remains illuminated the overheating condition remains and the system will automatically reduce engine power Neutral This lamp illuminates when the transmission is in INI neutral and the ignition key is in the ON position High Beam This lamp illuminates when the headlamp switch is set to high beam Check Engine This indicator appears if an 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 information center is located in the instrument cluster All seg ments 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 speedome ter If this occurs take th
100. play Units Standard Metric 38 45 Drive Belt Wear Burn 129 Drivetrain Break In 53 Driving Downhill 63 Driving in Reverse 67 Driving on a Sidehill 62 Driving on Slipperv Surfaces 60 Driving Over Obstacles 66 Driving Procedures 58 Driving Through Water 65 Driving Uphill 61 E Electromagnetic Interference 83 Electronic Power Steering 31 Emissions Limited Warranty 141 143 Engaging 4X4 2 33 Engine Break In 53 Engine Fogging 127 Engine Oil rene lees 89 0 EPS Warning Indicator 43 Equipment Modifications 9 Error Codes Engine 41 Etiquette Trail Riding 56 Exhaust Emission Control System 83 Extreme Use 30 AH Battery 31 Eye Protection 9 F Fluid Biake ecce oa esee 28 Coolant 2 re 96 98 Demand Drive 93 Engine Oil nre 89 9 Rear Gearcase 94 95 Transmission Qil 92 Fluid Change Demand Drive 93 Engine Oil oven 90 91 Rear Gearcase cee ee ee 95 Transmission 92 F Fluid Level Demand Drive 2 93 Engine Oll 2 RR 89 Rear Gearcase 94 Transmission sus 92 Foot Brake Auxiliarv 30 Footwell Removal 101 Front Compartment 51 Front Gearcase
101. properly in different situations and on different types of terrain Beginning and inexperienced operators should complete the recommended safety training before operating this vehicle See page 7 Never permit a guest to operate the ATV unless the guest has read this manual and all product labels and has completed a certified safety training course Age Restrictions This vehicle is an ADULT VEHICLE ONLY Operation is prohibited for anyone under 16 years of age 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 SAFETY Safety Warnings Handling Gasoline Gasoline is highly flammable and explosive under certain conditions Always exercise extreme caution whenever handling gasoline Always refuel with the engine stopped and outdoors or in a well ventilated area Do not smoke or allow open flames or sparks in or near the area where refu eling is performed or where gasoline is stored Do not overf
102. r 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 regions it s unlawful to operate ATVs on public streets roads and highways Operating at Excessive Speeds Operating the ATV at excessive speeds increases the operator s risk of losing control Always operate at a speed that s appropriate for the terrain the visibility and operating conditions and your experience 12 Safety Warnings Physical Control of the ATV Removing a hand from the handlebars or feet from the footrests during operation can reduce your ability to control the vehicle or cause loss of balance and ejection from the 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
103. rcase oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 85 See the table on page 88 for fluid recommendations capacities and plug torques See page 133 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 Fill Maintain the fluid level at the Level bottom of the fill hole threads Do not overfill Oil Check 1 Position the vehicle on a aa T level surface 2 Remove the fill plug Fill Plug Check the oil level Drain Plug 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 94 MAINTENANCE Rear Gearcase Oil Oil Change 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 95 MAINTENANCE Power Steering Unit If your model is equipped with power steering frequently clean the areas around and on the power steering unit to allow proper cooling Clean these areas thoroughly Steering Asse
104. rchase 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 139 WARRANTY 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 NOTICE If your product is registered outside of the country where it was purchased and you have not followed the procedure 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 outsid
105. rm any service that may be necessary for your vehicle POLARIS also recommends that you use only Pure 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 143 MAINTENANCE LOG Present this section of your manual to your dealer each time your vehicle is serviced This will provide you and future owners with an accurate log of maintenance and ser vices performed DATE MILES KM OR HOURS TECHNICIAN SERVICE PERFORMED COMMENTS
106. rops below a pre determined point See page 133 for the part numbers of POLARIS products 121 MAINTENANCE Battery Battery Charging The following battery charging instructions apply only to the installa tion of a sealed battery Read all instructions before proceeding with the installation of this battery The sealed battery is already filled with electrolyte and has been sealed and fully charged at the factory Never pry the sealing strip off or add any other fluid to this battery The single most important thing about maintaining a sealed battery is to keep it fully charged Since the battery is sealed and the sealing strip cannot be removed you must use a voltmeter or multimeter to measure DC voltage WARNING An overheated battery may explode causing severe injury or death Always watch charging times carefully Stop charging if the battery becomes very warm to the touch Allow it to cool before resuming charging For a refresh charge follow all instructions carefully 1 The battery should be disconnected from a load or charger for at least two hours before checking voltage Check the battery 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 manufac turer s instructions for recharging When usi
107. s 335 7 kg XP 750 Ibs 340 2 kg XP EPS 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 Capacity 9 3 oz 275 ml Transmission Oil Capacity 37 oz 1100 ml Front Rack Capacity 25 Ibs 11 3 kg Rear Rack Capacity 50 Ibs 22 7 kg Receiver Hitch Tongue Capacity 150 Ibs 68 kg Hitch Towing Rating 1500 Ibs 680 4 kg Unbraked Trailer Towing Capacity 1914 Ibs 868 kg Overall Length 82 5 in 209 5 cm Overall Width 48 in 122 cm Overall Height 49 5 in 125 7 cm Wheelbase 53 in 134 6 cm Ground Clearance 10 6 in 27 cm Minimum Turning Radius 84 in 213 cm unloaded 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 Idle RPM 1200 50 Throttle Body Size Mikuni Dual Bore 42 mm Spark Plug Type Gap AUTOLITE 5682 035 in 0 9 mm Lubrication System Wet Sump Driving System Type Automatic PVT POLARIS Variable Transmission Based on EU Directive 76 432 EC 134 SPECIFICATIONS SCRAMBLER XP 1000 1000 EPS Front Suspension Dual a arm with 9 2 23 cm travel XP Dual a arm with 9 2 23 cm travel XP EPS Progressive r
108. s are subjected to severe use grease zerks have been provided for additional lubrication at the user s discretion Item Recommended Capacity Fill Plug Drain Plug Inspection Lubricant at Fluid Torque Torque Procedure Change Engine Oil PS 4 5W 50 2 gt 12 ft lbs Page 89 4 Cycle Oil 1 91 16 Nm Transmission JAGL Gearcase 370z 10 14 ft Ibs 10 14 ft lbs Page 92 Oil Lubricant amp 1100 ml 14 19 Nm 14 19 Nm Transmission Fluid Demand Drive Demand Drive 9 3 oz 8 10 ft Ibs 11 ft lbs Page 93 Fluid Front Fluid 275 ml 11 14 Nm 15 Nm Gearcase Rear ATV Angle Drive 7 10z 10 14 ft Ibs 10 14 ft lbs Page 94 Gearcase Oil Fluid or GL5 80 210 ml 14 19 Nm 14 19 Nm 90 weight gear lube Brake Fluid DOT 4 Brake Page 28 Fluid Front Prop U Joint Grease Grease fittings 3 pumps maximum every 500 miles Shaft Yoke before long periods of storage or after pressure washing or submerging A Arms Front and Rear POLARIS All Season Grease Grease fittings after extreme use or if suspension becomes squeaky Front Prop Shaft Yoke 88 MAINTENANCE Engine Oil Oil Recommendations POLARIS recommends the use of POLARIS PS 4 Full Synthetic 5W 50 4 cycle oil or a similar oil for this engine Oil may need to be changed more frequently if POLARIS oil is not used Always use 5W 50 oil Follow the manufacturer s recomm
109. s fully seated when the load is attached F Never operate your winch with a d hook or latch Always replace damaged parts before using the winch YES NO 75 WINCH GUIDE Winch Operation 5 6 7 10 76 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 adhere to the following information for winch damping to ensure safe winch use A In order to absorb energy that could be released by a winch cable failure always place a damper on the winch cable A damper can be a heavy jacket tarp or other soft dense object A damper can absorb much of the energy released if a winch cable breaks when winching Even a tree limb can help as a damper if no other items are available to you 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 s
110. s original position Ensure the control cover seal is in place then reinstall the cover and screws 119 MAINTENANCE Battery 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 main tenance 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 termi nals with dielectric grease or petroleum jelly Battery Removal 1 Remove the front rack Disconnect the black negative battery cable first Disconnect the red positive battery cable last Disconnect the battery hold down strap Lift the battery out of the ATV A de X P9 120 MAINTENANCE Battery Battery Installation Using a new battery that has not been fully charged can damage the bat tery and result in a shorter life It can also hinder vehicle performance
111. ssibly 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 81 WINCH GUIDE Winch Maintenance and Service Safety WARNING Improper or lack of winch maintenance and service could lead to SEVERE INJURY or DEATH Always follow all winch instructions and warnings in this manual Always inspect your winch 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 authoriz
112. story of the unit Please see your Polaris dealer to retrieve inactive codes Use the following procedure to view active codes that occur when the key is on 1 Place the transmission in PARK 2 Press and release the SELECT button until the flashing check engine warning indicator appears in the display 3 Asetoftwo numbers will also appear in the display The 2 6 digit suspect parameter number SPN in the information area indicates which component is generating the fault code The 1 2 digit failure mode indicator FMI number in the clock area indi cates the fault mode such as open or short circuit 4 See pages 48 50 for code definitions and failure descriptions Tip More than one fault may be active Press and hold the MODE button to tog gle through all currently active diagnostic codes 47 FEATURES AND CONTROLS Instrument Cluster Diagnostic Display Code Definitions Open Load There is a break in the wires that lead to the item listed in the chart injector fuel pump etc or the item has failed Short to Ground The wire is shorted to ground between the electronic control unit and the item listed in the chart Shorted Load The wires leading to the item listed in the chart are shorted together or the item has shorted internally Short to Battery The wire leading from the item listed in the chart to the electronic control unit is shorted to a wire at battery voltage SCRAMBLER XP 1000 1000 EPS Dia
113. switch is set to the 4X4 position 2X4 Mode When the switch is on 2X4 the ATV is in two wheel drive at all times 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 while the rear wheels are spinning may cause severe drive shaft and gearcase damage Always switch to 4X4 while the rear wheels have traction or are at rest 33 FEATURES AND CONTROLS Instrument Cluster NOTICE High water pressure may damage ATV components Wash the ATV by hand or with a garden hose using mild soap Certain products including insect repellents and chemicals will damage the speedometer lens and other plastic surfaces Do not use alcohol to clean the instrument cluster Do not allow insect sprays to contact the lens Immediately clean off any gasoline that splashes on the instrument cluster Digital Analog Gauge Speedometer The speedometer displays vehicle speed in either miles
114. symbol alerts the operator that the preset service interval has been reached The vehi cle should be brought to your dealer for scheduled maintenance See page 46 for resetting instructions Under Over Voltage This warning usually indicates that the ATV is operating at an RPM too low to keep the battery charged It may also occur when the engine is at idle and high electrical load lights cooling fan accessories is applied Drive at a higher RPM or recharge the battery to clear the warning Check Engine Warning This icon displays if an EFI related fault occurs Do not operate the ATV if this warning appears Serious engine damage could result See your dealer 4X4 Display This icon displays when the 4X4 system is engaged switch is on either ADC 4X4 or 4X4 Neutral Indicator This indicator illuminates in addition to dis playing in the gear indicator display when the transmission is in neutral EPS Warning Indicator If this indicator light remains on after starting the engine the EPS system is inoperative See your autho rized Polaris dealer for service 43 FEATURES AND CONTROLS Instrument Cluster Multi Function Display MFD Gauge EPS Models Use the MODE button to toggle through the speed display options Use the SELECT button SEL to toggle through the information area options MODE and SELECT button opera tion is locked out at speeds above approximately 15 MPH 25 km h Tip The reverse overr
115. t 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 4 Move the stop switch either left or i right to the OFF position to stop the a engine quickly Move the stop switch CS to the RUN position before attempting to start the engine The engine will not OBP PUN OEP start or run when the switch is off Both the main switch and the engine stop switch will shut off all electri cal power to the vehicle including lights Main Key Switch Use the main key switch to start the engine See page 57 for starting pro cedures Automatic Transmission Gear Selector The transmission gear selector is Gear ope 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 engine speed above idle or while the vehicle is moving could cause transmission damage Whenever the ATV is left unattended always place the transmission in PARK and lock the parking brake Belt Life To extend belt life use low forward gear when pulling a heavy load at less than seven miles per hour for extended periods and when operating uphill at a slow speed PPZEOW 23
116. tand 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 80 For your safety always follow these guidelines when winching a vehicle free 12 A ro J K mmo o m 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 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 eve
117. ter depths and current before entering water cae EA Ss 2 Choose a crossing where dee ee both banks have gradual Mic a rs ae inclines Tj Maximum 3 Avoid operating through Pepin Ag deep or fast flowing water ss a 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 85 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 110 then see your dealer for service at the first opportunity 4 After leaving water test the brakes Apply them lightly several times while driving slowly The friction will help dry out the pads If it s unavoidable to enter water deeper than the footrest level Proceed slowly Avoid rocks and obstacles Balance your weight carefully Avoid sudden movements Maintain a steady rate of speed Do not make sudden turns or stops Do not make sudden throttle changes 65 OPERATION Driving Over Obstacles Follow these precauti
118. ter from the main filter Wash the pre filter in soapy water then rinse and let dry Reinstall the pre filter over the main filter Install a new main filter if needed Reinstall the filter into the air box Reinstall the air box cover and the seat Main Filter MAINTENANCE Fuse Replacement If the engine stops or will not start or if you experience other electrical failures a fuse may need replacement Locate and correct any short circuits that may have caused the blown fuse then replace the fuse 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 Reinstall the front rack Fuse Box 105 MAINTENANCE Lights Poor lighting can result in reduced visibility when driving Headlight and taillight lenses become dirty during normal operation Clean lights frequently and replace burned out lamps promptly Always make sure lights are adjusted properly for best visibility Headlight Beam Inspection The headlight beam can be adjusted slightly Use the following proce dure to make the adjustment 1 Position the vehicle on a level surface with the headlight approxi mately 25 ft 7 6 m from a wall Place the transmission in PARK 25 ft 7 6 m i Lamp Center Height 2 in 5 cm 2 Measure the distance from the flo
119. the engine 4 Onthe bottom of the vehicle a guard plate covers the oil filter access hole Remove the three bolts securing the guard plate and remove the guard plate 5 Clean the area around the drain plug 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 90 MAINTENANCE Engine Oil Oil and Filter Change 10 11 12 13 14 15 16 17 18 19 20 2l 22 23 Place shop towels beneath the oil fil ter Using an oil filter wrench avail able from your POLARIS dealer turn the filter counter clockwise to remove it Using a clean dry cloth clean the fil ter 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 by hand until the filter gas Oil Filter ket 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 Reinstall the guard plate over the filter access hole Pla
120. tions 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 Incorrectiv installed spark plug wires See vour dealer Incorrect ignition timing See vour dealer Mechanical failure See vour dealer Loose ignition connections Check all connections and tighten Water present in fuel Replace with fresh recommended fuel Leaking exhaust components See vour dealer 130 TROUBLESHOOTING Engine Pings or Knocks
121. val has been set Clock Mode Use one of the following two methods to reset the clock Method 1 1 Select the Hour Meter Mode 2 Press and hold the mode button on the instrument cluster until the hour display flashes Release the button 3 Press and release the SELECT button to advance the hours 4 Afterthe hours are set press and release the MODE button to move to the minutes Use the same procedure to reset the minutes 5 When the digits stop flashing the clock has been set Method 2 1 With the key turned off press and hold the MODE button 2 While still holding the MODE button turn the key to the ON posi tion 3 Continue to hold the MODE button until the hour display flashes Release the button 4 Setthe time as outlined in steps 3 5 of Method 1 46 FEATURES AND CONTROLS Instrument Cluster Multi Function Display MFD Gauge EPS Models 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 deter mination of persistent as well as intermittent faults Inactive codes are stored in the hi
122. ve a qualified dealer perform these operations Maintenance intervals in the following chart are based upon average rid ing conditions and an average vehicle speed of approximately 10 miles per hour Vehicles subjected to severe use must be inspected and ser viced more frequently Severe Use Definition Frequent immersion in mud water or sand Racing or race style high RPM use Prolonged low speed heavy load operation Extended idle Short trip cold weather operation Pay special attention to the oil level A rise in oil level during cold weather can indicate contaminants collecting in the oil sump or crank case Change oil immediately if the oil level begins to rise Monitor the oll level and if it continues to rise discontinue use and determine the cause or see your dealer 84 MAINTENANCE Periodic Maintenance Chart Maintenance Chart Key Symbol Description Perform these operations more often for vehicles subjected to severe use E Emission related service failure to conduct this maintenance will not void the emissions warranty but may affect emissions D Have an authorized POLARIS dealer perform these services 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
123. white A white insulator tip indicates overheating caused by use of an improper spark plug or incorrect fuel Wet Fouled Spark Plug The wet fouled insulator tip is black A damp oil film covers the firing end There may be a carbon layer over the entire nose Generally the electrodes are not worn General causes of fouling are excessive oil use of non recommended oil or incorrect throttle body adjustments 109 MAINTENANCE Vehicle Immersion If your vehicle becomes immersed major engine damage can result if the machine is not thoroughly inspected Take the vehicle to your dealer before starting the engine If it s impossible to take your ATV to a dealer before starting it follow the steps outlined below 1 2 ALS pe o9 Move the ATV to dry land or at the very least to water below the footrests Check the air box If water is present dry the air box and replace the filter with a new filter If equipped remove the air box drain plug to drain water Reinstall the drain plug Remove the spark plugs Turn the engine over several times using the electric start Dry the spark plugs Reinstall the plugs or install new plugs Attempt to start the engine If necessary repeat the drying proce dure NOTICE Serious damage can occur after immersion if fluids are not changed 7 110 promptly See your dealer as recommended Take the ATV to your dealer for service as soon as possible whether you succeed in starting it
124. wing instructions to dry it out before operat ing 1 2 114 Position the vehicle on a level surface Remove the drain plug Allow the water to drain completely Rein stall the drain plug Start the engine Place the transmission in PARK 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 Allow the engine RPM to settle to idle speed then shift the trans mission to the lowest available range Test for belt slippage If the belt slips repeat the process Take the vehicle to your dealer for service as soon as possible MAINTENANCE Handlebars The handlebars can be adjusted for rider preference WARNING Improper adjustment of the handlebars or incorrect torquing of the adjuster block tightening bolts can cause limited steering or loosening of the handlebars resulting in loss of control and serious injury or death Follow the adjustment procedures exactly or see your POLARIS dealer for service 1 Remove the upper headlight pod 2 Loosen the four handlebar bolts 3 Adjust the handlebar to the desired height Be sure the handlebars do not contact the gas tank or any other part of the machine when turned fully to the left or right 4 Torque the front two bolts to 10 12 ft lbs 14 17 Nm then torque the rear two bolts A gap of up to 1 8 3 mm will remain at the rear of the clamp blocks 115 MAINT
125. ymbols appear throughout this manual and on your vehicle Your safety is involved when these words and sym bols are used Become familiar with their meanings before reading the manual 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 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 Read this owner s manual Understand all safety warnings precautions and operating procedures before operating a POLARIS ATV Keep this manual with the AT

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