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Polaris X2 User's Manual

1. 124 129 Wheel Installation 95 Wheel Nut Torque Specifications 95 Wheel Removal 94 Worklight 100 Worklight Switch 36 133
2. A WARNING IMPROPER TIRE PRESSURE OR OVERLOADING can cause loss of control resulting in SEVERE INJURY OR DEATH TIRE PRESSURE IN PSI KPa FRONT 5 34 5 REAR 5 34 5 MAXIMUM WEIGHT CAPACITY Gross Vehicle Weight INCLUDING MACHINE OPERATOR PASSENGER AND CARGO IS 1500 LBS 680 kg Reduce speed and allow greater distance for braking when carrying cargo Overloading or carrying tall off center or unsecured loads will increase your risk of losing control Loads should be centered carried as low as possible in box and firmly secured to the rack For stability on rough or hilly terrain reduce speed and cargo Do not block headlight Be careful if load extends over the side of the rack or box Read Owner s Manual for more detailed loading information 7173900 ATTENTION Operation of this vehicle without the air filter element will severely damage the engine Clean pre filter element often more frequent cleaning required in dusty conditions Do not operate vehicle without pre filter 7172921 SAFETY Safety Decals and Locations A WARNING Es Operating this vehicle if you are under the age of 16 increases your chance of severe injury or death NEVER operate this ATV if you are under age 16 7172588 A 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 combined Front Rack and container Load 90 Ibs 4
3. Noise Emission Control System Oil Filter Change Oil Pump Priming Parking on an Incline Passenger Seat Periodic Maintenance Chart Polaris Products Pre Ride Inspection Premium 4 Synthetic Lubricant Radiator Coolant Level Reverse Override Switch Rider Information Center INDEX S Safe Riding 13 Safety Decals and Locations 6 11 Safety Training 12 Seat Conversion 44 Setting the Parking Brake 40 Severe Use esce EE 74 Side Panel Removal 93 Sidehilling ss 62 Spark 103 Spark 101 Specifications 122 123 Starting the Engine 55 Steering Assembly 92 Stop 36 Storage seva ees eee 110 113 Storage Tips 111 113 Switches Ved es dese S 36 T Tachometer 48 sk eee ees 100 Throttle Body 116 Throttle Cable Freeplay 116 Throttle 37 Tires 94 Toe Alignment 92 Towing 71 Transmission Oil 85 86 Transporting the ATV 114 Trip Metet use aes Caged 48 Troubleshooting 118 121 Turning Around on aHill 64 65 V Vehicle Identification Numbers 5 Vehicle Immersion 102 W Warranty
4. 130 INDEX 132 VEHICLE IDENTIFICATION NUMBERS Record your ATV s identification numbers and key number in the spaces provided Remove the spare key and store it in a safe place Your key can be duplicated only by mating a Polaris key blank with one of your existing keys so if both keys are lost the ignition switch must be replaced Vehicle Model Number Frame VIN 1 Engine Serial Number 2 Key Number 3 SAFETY Safety Decals and Locations Warning decals have been placed on the ATV for your protection Read and follow the instructions of the decals on the ATV carefully If any of the decals depicted in this manual differ from the decals on your always read and follow the instructions of the decals on the ATV If any decal becomes illegible or comes off contact your Polaris dealer to purchase a replacement Replacement safety decals are provided by Polaris at no charge The part number is printed on the decal AWARNING Never operate this vehicle on HILLS steeper than 15 degrees To prevent flipover on hilly terrain when going up or down use throttle and brakes gradually Never operate this vehicle in TURF mode on irregular terrain including hills and obstacles REVERSE operation can be dangerous even at low speeds Steering becomes difficult To prevent flipover avoid sudden braking or sharp turns Use OVERRIDE for reverse speed limiter
5. WHAT CAN HAPPEN The vehicle could overturn HOW TO AVOID THE HAZARD Maintain steady speed when climbing a hill If all forward speed is lost Lean forward to keep body weight uphill A passenger should also lean uphill Apply the single lever brakes Lock the parking brake when fully stopped Dismount on the uphill side of the vehicle or on the left if the vehicle is pointing straight uphill Have a passenger dismount first then the operator may dismount Turn the ATV around and remount following the procedure described in the owner s manual See page 64 If the ATV begins rolling backwards Keep operator and passenger body weight uphill Never apply engine power Never apply the rear brake while rolling backwards Apply the single lever brake gradually When fully stopped apply the foot brake as well and then lock the parking brake Dismount on the uphill side of the vehicle or on the left if the vehicle is pointing straight uphill Have a passenger dismount first then the operator may dismount Turn the ATV around and remount following the procedure described in the owner s manual See page 64 31 SAFETY Rider Safety 4 WARNING 32 POTENTIAL HAZARD Improperly operating over obstacles WHAT CAN HAPPEN Operating over obstacles could cause loss of control or overturn HOW TO AVOID THE HAZARD Before operating in a new area check for obstacles Avoid operating over large obstacles such
6. If you move to another country be sure to contact Polaris Customer Assistance and the customs department of the destination country be fore you move Vehicles importation rules vary considerably from country to country You may be required to present documentation of your move to Polaris Industries in order to continue your warranty cov erage You may also be required to obtain documentation from Polaris Industries in order to register your vehicle in your new country 127 WARRANTY Exported Vehicles How to Get Service If Purchased From A Private Party If you purchase a Polaris product from a private citizen outside of the country in which the vehicle was originally purchased all warranty coverage will be denied Notice If your vehicle is registered outside of the country where it was pur chased and you have not followed the procedure set out above your vehicle will no longer be eligible for warranty or service bulletin cover age of any kind Vehicles registered to Government officials or mili tary personnel on assignment outside of the country where the vehicle was purchased will continue to be covered by the basic warranty For questions call Polaris Customer Assistance United States 1 763 417 8650 Canada 1 204 925 7100 128 WARRANTY U S A EPA Emissions Limited Warranty This All Terrain Vehicle ATV or Off Road Utility Vehicle ORUV emissions limited warranty is in addition to the Polaris standard limit
7. AR WN Select a level site to dump the cargo box Do not attempt to dump or unload the vehicle while parked on an incline Place the transmission in PARK Lock the parking brake Dismount the vehicle Lower the tailgate A WARNING 9 If cargo weight is placed toward the rear of the cargo box the load may dump unexpectedly and cause serious injury When loading cargo always position the weight as far forward and as low as possible Pull the cargo box release lever A upward Lift the front of the cargo box and dump the cargo Lower the cargo box and make sure the release latch is secured Secure the tailgate 4 WARNING 72 Operating with the cargo box in the raised position can cause serious injury and damage to the vehicle The cargo box could close unexpectedly and injure the driver The rear tires will also catch the rear of the bed damaging the vehicle and creating hazardous driving conditions Never operate this vehicle with the cargo box in the raised position EMISSION CONTROL SYSTEMS Noise Emission Control System Do not modify the engine intake or exhaust components as doing so may affect compliance with U S A EPA noise control requirements 40 CFR 205 and local noise level requirements Operation on Public Lands in the U S A Your Polaris vehicle has a spark arrestor that was tested and qualified to be in accordance with the USDA Forest Service Standard 5100 1C Federal law requires
8. HOW TO OBTAIN WARRANTY SERVICE If your ATV requires warranty service you must take it to a Polaris dealer authorized to repair Polaris ATVs When requesting warranty service you must present your copy of the Warranty Registration form to the dealer THE COST OF TRANSPORTATION TO AND FROM THE DEALER IS YOUR RESPONSIBILITY Polaris suggests that you use your original selling dealer however you may use any Polaris Servicing Dealer to perform warranty service Please work with your dealer to resolve any warranty issues Should your dealer require any additional assistance they will contact the appropriate person at Polaris This warranty gives you specific legal rights and you may also have other rights which vary from state to state If any of the above terms are void because of state or federal law all other warranty terms will remain in effect Engine Oil 1 Mixing oil brands or using non recommended oil may cause engine damage We recommend the use of Polaris engine oil for your ATV 2 Damage resulting from the use of non recommended lubricants may not be covered by warranty SPARK ARRESTOR Polaris warrants that the spark arrestor in this vehicle will meet the efficiency requirements of 43 CFR 8340 1 c for 1000 hours when subjected to normal use and when maintenance and installation are in accordance with Polaris recommendations 126 WARRANTY Exported Vehicles EXCEPT WHERE SPECIFICALLY REQUIRED BY LAW THERE I
9. The engine exhaust from this product contains chemicals known to cause cancer birth defects or other reproductive harm A card containing important ATV safety information should be attached to the owner s manual on the next page If you cannot locate this card or if it has been removed please call 1 800 342 3764 for assistance WELCOME Thank you for purchasing a Polaris vehicle and welcome to our world wide family of Polaris owners We proudly produce an exciting line of utility and recreational products Snowmobiles All terrain vehicles ATVs RANGER utility vehicles Victory motorcycles We believe Polaris sets a standard of excellence for all utility and recreational vehicles manufactured in the world today Many years of experience have gone into the engineering design and development of your Polaris vehicle making it the finest machine we ve ever produced For safe and enjoyable operation of your vehicle be sure to follow the instructions and recommendations in this owner s manual Your manual contains instructions for minor maintenance but information about major repairs is outlined in the Polaris Service Manual and should be performed only by a Factory Certified Master Service Dealer MSD Technician Your Polaris dealer knows your vehicle best and is interested in your total satisfaction Be sure to return to your dealership for all of your service needs during and after the warranty period We
10. POLARIS The Way Out sportsman X2 200 EFI 2006 Owner s Manual for Maintenance and Safety AWARNING Improper vehicle use can result in SEVERE INJURY or DEATH ALWAYS USE NEVER USE NEVER CARRY NEVER USE AN APPROVED ON PUBLIC MORE THAN WITH DRUGS HELMET AND ROADS ONE OR ALCOHOL PROTECTIVE GEAR PASSENGER FOR OPERATOR AND PASSENGER NEVER operate e without proper training or instruction e at speeds too fast for your skills your passenger s skills or the conditions on public roads a collision can occur with another vehicle e with more than one passenger passengers affect balance and steering and increase risk of losing control e with a passenger under the age of 12 THE OPERATOR MUST ALWAYS use proper riding techniques to avoid vehicle overturns on hills and rough terrain and in turns avoid paved surfaces pavement may adversely affect handling and control e reduce speed and use extra caution at all times when carrying a passenger have passenger dismount when conditions require e make sure passenger reads and understands this label and passenger safety label LOCATE AND READ OWNER S MANUAL FOLLOW ALL INSTRUCTIONS AND WARNINGS a om For your nearest Polaris dealer C POLRRIS soroans The Way Out or visit www polarisindustries com Polaris Sales Inc 2100 Hwy 55 Medina MN 55340 Phone 763 417 8650 Fax 763 542 0599 Part No 9920361 Rev 02 Printed in USA A WARNING
11. 20 minutes of operation for the stabilizer to disperse through the fuel in the tank Oil and Filter Warm the engine and change the oil and filter Air Filter Air Box Inspect and clean or replace the pre cleaner and air filter Clean the air box and drain the sediment tube Breather Filter Inspect and clean or replace the breather filter Fluid Levels Inspect the following fluid levels and change if necessary Front demand drive unit front gearcase Transmission Brake fluid change every two years or as required if fluid looks dark or contaminated 111 MAINTENANCE Cleaning and Storage Storage Tips Fog the Engine 1 Treat the fuel system with Polaris Carbon Clean following the instructions on the can Run the engine for several minutes so the Carbon Clean reaches the injector Turn the engine off Remove the spark plug and add 2 3 tablespoons of Premium 4 Synthetic 0W40 engine oil To access the plug holes use a section of clear 1 4 hose and a small plastic squeeze bottle filled with the pre measured amount of oil NOTE Do this carefully If you miss the plug holes oil will drain from 112 the spark plug cavities into the hole at the front of the cylinder head and appear to be an oil leak Reinstall the spark plug Torque to 18 ft Ibs 24 Nm Apply dielectric grease to the inside of the spark plug cap and reinstall the cap onto the plug Turn the engine over several times Oil will be forced in
12. 3 Install the wheel nuts and finger tighten 4 Lower the vehicle to the ground 5 Torque the wheel nuts to specification f 1 1 2 4 90 ft Ibs 27 ft Ibs 122 Nm 37 Nm Cast Aluminum Steel Wheel Nut Torque Specifications Check the wheel nut torques occasionally and when they ve been loosened for maintenance service Nut Type 1 Lug Nut 90 ft Ibs 122 Nm 2 2 Piece Flange Nut 27 ft Ibs 37 Nm 95 MAINTENANCE Filter Systems Air Filter Service 1 6 Remove the seat release the air box cover clips and remove the air box cover Loosen the clamp and remove the filter Remove the fabric type pre filter 1 from the main filter 2 Wash the pre filter in soapy water then rinse and let dry Reinstall the pre filter over the main filter Replace the main filter if needed Reinstall the filter into the air box and tighten the clamp Do not over tighten the clamp as filter damage could occur Reinstall the air box cover and the seat Breather Filter Hose 1 2 To access the breather filter 3 remove the left side panel as outlined on page 93 The breather filter is on the hose that runs between the engine and air box Remove the clamps and pull the filter out of the hoses NOTE It s not necessary to remove the lower hose from the engine 3 4 3 Inspect the filter for debris Blow gently through the filter in the direction of the arrow to check
13. ATV in the 2 up mode with a passenger Reduce speed and allow a greater distance for braking When operating over rough or hilly terrain reduce speed and cargo to maintain stable driving conditions WEIGHT DISTRIBUTION in the cargo bed should be as far for ward and as low as possible Carrying a high load raises the center of gravity and creates a less stable operating condition Reduce load weight when cargo is high When handling off centered loads that cannot be centered secure the load and operate with extra caution ALL LOADS MUST BE SECURED BEFORE OPERATING Unsecured loads may shift and create unstable operating condi tions which could result in loss of control of the vehicle Always be sure that the cargo bed is lowered and latched before mov ing the vehicle EXTREME CAUTION MUST BE USED when operating with loads extending beyond the rack or cargo bed Stability and maneuverability may be adversely affected causing the ma chine to overturn Carrying a load on only the front rack or cargo bed may cause an imbalanced condition and increases the possibility of vehicle overturn Balance loads proportionally between the front rack and cargo bed but do not exceed the stated load capacity Use extreme caution when applying brakes with a loaded ve hicle Avoid terrain or situations that may require backing down hill Always attach the tow load to the hitch point The vehicle should never exceed 10
14. 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 35 CONTROLS Engine Electrical Switches 4 WARNING Activating the override switch while the throttle is open can cause loss of control resulting in severe injury or death Do not activate the override switch while the throttle is open 4 Wd CY ff y meet Ne 9 3 Mode Reverse Override Switch 1 This vehicle is equipped with a reverse speed limiter system To gain additional power while backing depress the override switch NOTE The override switch also allows activation of AWD in reverse if the AWD switch is on This switch is also used to toggle through the different modes of the rider information center See page 46 Engine Stop Switch 2 The engine will not start or run when the switch is in the OFF RUN OFF OFF position Its purpose is to provide the operator with a quick means of engine shutdown in case of an emergency Main Switch 3 To start the engine slide the stop switch to the center RUN position and turn the main key switch clockwise past the ON position Release the key when the engine starts NOTE Both the main switch and the emergency engine stop switch will shut off all electrical power to the vehicle including lights To stop the engine slide the stop switch either right or left to the
15. Poor maintenance increases the possibility of an accident or equipment damage HOW TO AVOID THE HAZARD Always inspect your ATV before each use to make sure it s in safe operating condition Always follow the inspection and maintenance procedures and schedules described in the owner s manual 24 SAFETY Rider Safety 4 amp WARNING POTENTIAL HAZARD Operating on frozen bodies of water WHAT CAN HAPPEN Severe injury or death can result if the ATV and or the operator fall through the ice HOW TO AVOID THE HAZARD Never operate the ATV on a frozen body of water 4 WARNING POTENTIAL HAZARD Removing hands from the handlebars or feet from the footrests during operation WHAT CAN HAPPEN Removing even one hand or foot can reduce ability to control the vehicle or could cause loss of balance and ejection from the ATV If a person s feet are not firmly planted on the footrests they could come into contact with the wheels or other moving parts and lead to accident or injury HOW TO AVOID THE HAZARD Always keep both hands on the handlebars and both feet on the footrests of the ATV during operation A passenger should always be seated in the passenger seat with both feet on the footrests and both hands on the passenger grab handles at all times The passenger should never hold on to the operator 25 SAFETY Rider Safety 4 WARNING POTENTIAL HAZARD Failure to use extra caution when operating the ATV o
16. Reinstall the harness connector 8 Test the light for proper operation 9 Reinstall the taillight assembly 10 Reinstall the two screws 100 MAINTENANCE Spark Plugs Always use the spark plugs recommended for your ATV Refer to the specifications section beginning on page 122 for the recommended spark plug type and gap CAUTION Using non recommended spark plugs can result in serious engine damage Always use Polaris recommended spark plugs Spark plug condition is indicative of engine operation The spark plug firing end condition should be read after the engine has been warmed up and the vehicle has been driven at higher speeds Immediately check the spark plug for correct color 4 WARNING A hot exhaust system and engine can cause serious burns Wear protective gloves when removing a spark plug for inspection 1 Normal The normal insulator tip is gray tan or light brown There will be few combustion deposits The electrodes are not burned or eroded This indicates the proper type and heat range for the engine and the service NOTE The should not be white A white insulator tip indicates overheating caused by use of an improper spark plug or incorrect fuel 2 Wet Fouled 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
17. age to operate this ATV Never allow anyone under 12 years of age to ride as a passenger on this 2 up ATV Make sure any passenger is tall enough to comfort ably and safely reach the handgrips and footrests Never secure a passenger to the vehicle or to the operator with a belt rope or similar device Never carry more than one passenger on this 2 up ATV Always make sure the passenger seat lock out is functioning proper ly before carrying a passenger Never permit a guest to operate the ATV unless the guest has read this manual and all product labels and has completed a certified safe ty training course Always keep both hands on the handlebars and both feet on the foot rests of the ATV during operation A passenger should always be seated in the passenger seat with both feet on the footrests and both hands on the passenger grab handles at all times The passenger should never hold on to the operator Always avoid operating an ATV on paved surfaces including side walks driveways parking lots and streets Never operate an ATV on a public street road or highway including a dirt or gravel road Never ride an ATV without wearing an approved helmet that fits properly Always wear eye protection goggles or face shield gloves boots a long sleeved shirt or jacket and long pants A pas senger s helmet should have a rigid chin guard Never consume alcohol or drugs before or while riding an ATV 15 SAFETY
18. and release the brake lever It will return to its unlocked position Important Safeguards The parking brake may relax if left on for a long period of time AI ways 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 40 CONTROLS Auxiliary Brake 4 WARNING Aggressively 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 Your Polaris ATV has an auxiliary brake for added safety It s located on the inside of the right floor board and is operated by the right foot The auxiliary brake serves as a backup to the main brake system if the main system becomes inoperative If the rear wheels slide while using the auxiliary brake reduce brake pedal pressure to brake the rear wheels without skidding Brake Fluid Level Check the brake fluid level frequently for the auxiliary brake system The reservoir is located under the seat or near the auxiliary brake Maintain the fluid level between the maximum and
19. as rocks and fallen trees when possible If unavoidable use extreme caution and always follow proper procedures as outlined in the owner s manual Always have a passenger dismount before operating over an obstacle that could cause a fall from the vehicle or vehicle tipover WARNING POTENTIAL HAZARD Skidding or sliding WHAT CAN HAPPEN Skidding or sliding can cause loss of control If the tires regain traction unexpectedly the ATV could overturn HOW TO AVOID THE HAZARD On slippery surfaces such as ice travel slowly and use extra caution to reduce the chance of skidding or sliding out of control WARNING POTENTIAL HAZARD Improperly operating in reverse WHAT CAN HAPPEN The ATV could collide with an obstacle or person resulting in severe injury HOW TO AVOID THE HAZARD Before shifting into reverse gear always check for obstacles or people behind the ATV When it s safe to proceed back slowly Be aware that a passenger can obstruct your view SAFETY Rider Safety 4 amp WARNING POTENTIAL HAZARD Operating the ATV through deep or fast flowing water WHAT CAN HAPPEN Tires may float causing loss of traction and loss of control which could lead to an accident or overturn HOW TO AVOID THE HAZARD Avoid operating the ATV through deep or fast flowing water If it s unavoidable to enter water that exceeds the recommended maximum depth see page 66 travel slowly balance your weight carefully avoid sudden movem
20. cable Reinstall the battery cover and attach the hold down strap Verify that cables are properly routed NOTE When installing a new battery make sure it s fully charged prior to its initial use Using a new battery that has not been fully charged can damage the battery and result in a shorter life It can also hinder vehicle performance 107 MAINTENANCE Battery Battery Storage When the vehicle is placed in storage for three months or more the battery should be removed stored out of the sun in a cool dry place and tested monthly Before reusing take the battery to your dealer for testing and recharging Power plug leads may need to be bent down so that the battery cover can be installed Replenishing Battery Fluid Conventional Battery A poorly maintained battery will deteriorate rapidly Check the battery fluid level often The fluid level should be kept between the upper and lower level marks 1 To refill use only distilled water Tap water contains minerals that are harmful to a battery 4 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 Battery Charging Sealed Battery The following battery charging instructions apply only to the installation of a YUASA activated s
21. cap while the engine is warm or hot Always allow the engine to cool before removing the pressure cap 1 To access the radiator pressure cap open the front box lid and pull open the access door 2 Remove the pressure cap 1 3 Using a funnel slowly add coolant through the radiator filler neck 4 Reinstall the pressure cap secure the access door and close the box NOTE Use of a non standard pressure cap will not allow the recovery system to function properly Contact your dealer for the correct replacement part 88 Engine Cooling System Coolant Level The recovery bottle 1 is located on the left side of the machine To access the recovery bottle remove the left side panel as outlined on page 93 Maintain the coolant level between the minimum and maximum marks on the bottle when the fluid is cool Add coolant as needed Cooling System Operation MAINTENANCE The engine coolant level is controlled or maintained by the recovery system The recovery system components are the recovery bottle radiator filler neck radiator pressure cap and connecting hose As coolant operating temperature increases the expanding heated excess coolant is forced out of the radiator past the pressure cap and into the recovery bottle As engine coolant temperature decreases the contracting cooled coolant is drawn back up from the tank past the pressure cap and into the radiator NOTE Some coolant level drop
22. for clogging Replace if needed Check the hoses for cracks deterioration abrasion or leaks Replace as needed Reinstall the filter and secure the clamps NOTE The filter is effective with the arrow pointing in either 96 direction CAUTION Operation of your vehicle without a breather filter can cause engine damage Always reinstall the breather filter after removing for service MAINTENANCE Lights When servicing a halogen lamp don t touch the lamp with bare fingers Oil from your skin leaves a residue causing a hot spot that will shorten the life of the lamp 4 WARNING Poor lighting while driving can result in severe injury or death Headlight and taillight lenses become dirty during normal operation Wash the headlights frequently to maintain lighting quality Hot components can cause serious burns to skin Allow lamps to cool before servicing Headlight Lamp Replacement 1 Remove the two screws on the lower front corners of the headlight pod 2 Remove the screw from the rear of the pod 3 Lift the pod slightly while depressing the tabs at the rear of the pod 4 Lift the pod cover and disconnect the speedometer harnesses from the speedometer 5 Unplug the headlamp from the wiring harness Be sure to pull on the connector not on the wiring 6 Turn the lamp counterclockwise to remove it 7 Apply dielectric grease to the socket and install the new lamp NOTE Make sure the tab on the lamp l
23. handling 4 Vary the throttle positions Do not operate at sustained idle 5 Perform regular checks on fluid levels controls and areas outlined on the daily pre ride inspection checklist See page 54 6 Pull only light loads 7 During the break in period change both the oil and the filter at 20 hours 200 miles or one month whichever comes first PVT Break in Clutches Belt A proper break in of the clutches and drive belt will ensure a longer life and better performance Break in the clutches and belt by operating at slower speeds during the break in period as recommended Pull only light loads Avoid aggressive acceleration and high speed operation during the break in period 53 OPERATION Pre Ride Inspection 4 WARNING If a proper inspection is not done before each use severe injury or death could result Always inspect the vehicle before each use to ensure it s in proper operating condition Pre Ride Checklist Ensure proper operation Ensure proper operation Ensure proper level Ensure proper operation Inspect lubricate if necessary Inspect lubricate if necessary Ensure free operation nspect condition and pressure nspect ensure fastener tightness nspect ensure tightness Ensure proper levels wl cof Of aw A aj R Ensure proper operation Ensure operation Ensure proper operation Drain deposits whenever visible Headlam
24. in AWD and the differential is locked When in AWD the front gearcase will automatically engage any time the rear wheels lose traction When the rear wheels regain traction the front gearcase will automatically disengage There is no limit to the length of time the vehicle may remain in AWD NOTE The override switch allows activation of AWD in reverse if the AWD switch is on See page 36 When the switch is on TURF right position the differential is open allowing the inside wheel to rotate independently from the outside wheel during turns Operate this vehicle in TURF mode only to protect smooth level surfaces from tire damage Otherwise switch out of TURF mode 4 WARNING Operating in TURF mode when on sloped uneven or loose terrain could cause loss of control and result in serious injury or death One rear wheel may slip and lose traction or may lift up and grab when it touches the ground again DO NOT operate in TURF mode when climbing or descending hills when sidehilling or when operating on uneven loose or slippery terrain conditions such as sand gravel ice snow obstacles and water crossings Switch the All Wheel Drive AWD system out of TURF mode whenever it is not required 43 FEATURES All Wheel Drive AWD System Engaging Front Gearcase The AWD switch may be turned on or off while the vehicle is moving Initially the vehicle s electronic system will not enable the AWD until the engine RPM is bel
25. meter select the trip meter mode Press and hold the mode button override button until the total changes to 0 NOTE Inthe Rider Information Center the trip meter display contains a decimal point but the odometer displays without a decimal point Mode 3 Hour Meter This mode logs the total hours the engine has been in operation Mode 4 Tachometer The engine RPM is displayed digitally NOTE Small fluctuations in the RPM from day to day may be normal because of changes in humidity temperature elevation and electrical loads 48 FEATURES Instrument Cluster Rider Information Center Diagnostic Mode The diagnostic mode is for informational purposes only Please return your ATV to your dealer for all major repairs As long as the gauge is in the diagnostic mode the wrench icon will remain lit To leave the diagnostic mode turn the key switch off and on NOTE Any movement of the tires will also take the machine out of the diagnostic mode To enter the diagnostics mode Turn the key switch off and wait 10 seconds Lock the parking brake Place the transmission in neutral Hold the mode reverse override button and turn the key switch on Release the switch as soon as the display is activated Ua The initial screen display refers to the software version installed in your ATV This information is displayed briefly Use the mode reverse override button to toggle through the diagnostic screens Sc
26. paths parking lots and driveways WHAT CAN HAPPEN ATV tires are designed for off road use Operating on paved surfaces may seriously affect the handling and control of the ATV and could result in loss of control accident and or injury HOW TO AVOID THE HAZARD Avoid operating the ATV on pavement If it s unavoidable travel slowly and avoid sudden turns or stops 4 WARNING POTENTIAL HAZARD KF Operating this ATV on public streets roads or highways WHAT CAN HAPPEN n The ATV could collide BEN with another vehicle HOW TO AVOID THE HAZARD Never operate the ATV on any public street road or highway including dirt and gravel roads In many areas it s illegal to operate ATVs on public streets roads and highways 21 SAFETY Rider Safety 4 WARNING POTENTIAL HAZARD Riding an ATV without wearing an approved helmet eye protection and protective clothing WHAT CAN HAPPEN Riding an ATV without an approved helmet increases the risk of a severe head injury or death in the event of an accident Riding without eye protection could result in an accident and could increase the chance of a severe injury in the event of an accident HOW TO AVOID THE HAZARD Always be sure operator and passenger wear an approved helmet that fits properly A passenger s helmet should have a rigid chin guard Always be sure operator and passenger wear eye protection goggles or face shield gloves boots a
27. procedures You should review this information on a regular basis If you purchased a used Polaris ATV you can take the ATV RiderCourse by calling ATV Enrollment Express at 800 887 2887 or by visiting www atvsafety org Purchasers of a used Polaris ATV will be charged for this training A Polaris ATV is an off road vehicle Familiarize yourself with all laws and regulations concerning the operation of the ATV in your area We strongly advise you to strictly follow the recommended maintenance program outlined in your owner s manual This preventive maintenance program is designed to ensure that all critical components on your vehicle are thoroughly inspected at specific intervals Age Restrictions This vehicle is an ADULT VEHICLE ONLY Operation is prohibited for anyone under 16 years of age Never allow anyone under 12 years of age to ride as a passenger on this 2 up ATV Know Your Vehicle As the operator of the vehicle you are responsible for your personal safety the safety of others including your passenger and the protection of our environment Read and understand your owner s manual which includes valuable information about all aspects of your vehicle including safe operating procedures 12 SAFETY Safe Riding Gear Always wear clothing suited to the type of riding ATV riding requires special protective clothing for comfort and to reduce the chance of injury 1 Helmet Your helmet is the most important piece o
28. the fitting NOTE The fitting threads must be sealed with LOCTITE PST 505 or PTFE seal tape 8 Reinstall the screen fitting and rotate the fitting clockwise a minimum of 2 1 2 turns into the tank threads Continue to rotate the fitting until the nipple of the fitting aligns with the mark 4 on the tank NOTE Do not over tighten Maximum torque for the screen fitting is 25 ft Ibs 34 Nm 9 Reattach the oil line 82 MAINTENANCE Oil Change 10 11 12 13 NOTE The sealing surfaces on 14 15 Place shop towels beneath the oil filter Using an oil filter wrench turn the filter 1 counterclockwise and remove Lubricate the gasket on the new filter with a film of new engine oil Check to make sure the gasket is in good condition Also make sure the gasket from the old filter is not still on the engine Install the new filter and tighten by hand 1 2 to 3 4 turn after gasket contacts the engine Approximately one cup of engine oil will remain in the crankcase To drain remove the drain plug on the lower right side of the crankcase the drain plug and crankcase should be clean and free of burrs nicks or scratches Reinstall the drain plug Torque to 14 ft Ibs 19 Nm Remove the dipstick 2 and add two quarts 1 9 1 of the recommended oil Reinstall the dipstick NOTE Ifthe sump is not drained add about 1 3 4 quarts 1 6 1 16 17 18 19 20 initially Plac
29. the ATV NOTE A rising oil level between checks in cool weather driving can indicate contaminants such as gas or moisture collecting in the crankcase If the oil level is over the full safe mark change the oil immediately 1 Position the vehicle on a level surface 2 Start the engine and let it idle for 20 30 seconds Stop the engine 3 Remove the dipstick and wipe it dry with a clean cloth 4 Reinstall the dipstick completely 5 Remove the dipstick and check the oil level Maintain the oil level in the normal or safe range 2 Do not overfill ADD 8 OZ NORMAL FULL 6 Reinstall the dipstick securely 2 81 MAINTENANCE Oil and Filter Change Change the oil and filter at the intervals outlined in the Periodic Maintenance Chart beginning on page 74 1 Position the vehicle on a level surface 2 Clean the area around the drain plug at the bottom of the oil tank and the bottom of the engine 3 Run the engine for two to three minutes then turn it off 4 Place a drain pan beneath the oil tank and remove the drain plug 1 Allow the oil to drain completely 5 Install a new sealing washer 2 on the oil drain plug NOTE The sealing surfaces on the drain plug and the oil tank should be clean and free of burrs nicks or scratches 6 Reinstall the drain plug Torque to 14 17 ft Ibs 19 23 Nm 7 Disconnect the lower oil delivery hose and remove the screen fitting 3 from the oil tank Clean
30. 1 kg 7172569 A WARNING Passengers can be thrown off This can cause serious injury or death Never carry passengers In cargo 7172880 WARNING Remove flammable material containers from box before filling WARNING Passengers can be thrown off This can cause serious injury or death Never carry passengers in cargo box Max Box Load 400 Ibs 181 kg SAFETY Safety Decals and Locations 10 PASSENGER SAFETY To reduce the risk of SEVERE INJURY or DEATH NEVER CARRY NEVER CARRY NEVER RIDE AFTER A PASSENGER MORE THAN ONE USING DRUGS OR UNDER AGE 12 PASSENGER ALCOHOL NEVER carry a passenger too small to firmly plant feet on footrests and securely grasp hand holds THE PASSENGER MUST ALWAYS use an approved helmet and protective gear securely grasp hand holds and plant feet firmly on footrests tell operator to slow down or stop if uncomfortable get off and walk if conditions require 7174028 SAFETY Safety Decals and Locations A WARNING Moving parts h d under belt clutch guard To prevent serious injury do not operate vehicle with guard removed Do not modify engine or clutch Doing so can cause part failure possible imbalance and excessive engine RPM which can result in serious injury or death NO STEP 7172563 4 WARNING Pushing reverse MANUFACTURED BY POLARIS IND INC override button may cause sudden increases
31. 5 116 Age Restrictions 12 Air Filter 96 All Wheel Drive 43 44 Automatic Transmission 42 Auxiliary Brake 91 AWD 43 44 B Battery Rue 107 109 Battery Conventional 106 Battery Charging Sealed 108 109 Battery Fluid Conventional 108 Battery Installation 107 Battery Removal 107 Battery Storage 108 Belt 53 Belt Lite irs be 42 Brake Fluid 39 41 Brake Lever 38 Brake Auxiliary 41 Brakelight 100 Brakes biden E RATE 90 91 Break In 53 Breather 96 C Camber and Caster 115 Cleaning 110 113 Clutch 53 Clutching 123 Cold Weather Operation 25 Coolant Level 89 Cooling System 89 Cooling System Operation 89 Crankcase Emission Control System 73 D Diagnostic Mode 51 Diagnostic Mode Instrumentation 49 50 Drivetrain Break In 53 Driving Downhill 63 Driving in Reverse 68 Driving on aHillside 62 Driving on Slippery Surfaces 60 Driving Over Obstacles 69 Driving Procedures
32. 56 Driving Through Water 66 67 132 D Driving Uphill 61 Driving With a Passenger 58 59 Dumping Cargo 72 E Electrical Switches 36 Emission Control Systems 73 Emissions Warranty 129 Engaging Front Gearcase 44 Engine Break In 53 Engine Cooling System 88 Engine Stop Switch 36 Equipment Modifications 18 Exhaust Emission Control System 73 F Filter Systems 96 Footwell Removal 93 Front Gearcase Oil 87 Front Wheel Hub Tightening 94 Fuel Filter 00 0 0 000 42 Fuel Safety 52 Fuel Tank 422 0 ELSE 42 G Gear 1 42 H Handlebars 115 Hauling 70 72 Headlamp Lower 100 Headlight Housing Replacement 99 Headlight Lamp Replacement 97 High Beam Adjustment 98 High 104 Hour 48 1 Idle RPM 116 Instrument Cluster 46 51 K K T rn 424 wRLEAAD eek ea 64 L Light Switches 38 Lights eli Yer 97 100 Load Distribution 71 Low Beam Adjustment 98 Low Range 104 Lubrication Guide 79 Maintenance Chart Maintenance Log Master Cylinder Mode Reverse Override Switch
33. Cause Solution Poor quality or low octane fuel Replace with recommended fuel Incorrect ignition timing See your Polaris dealer Incorrect spark plug gap or heat range Set gap to specs or replace plug Engine Runs Irregularly Stalls or Misfires Possible Weak Spark Cause Solution Other mechanical failure Possible Lean Fuel Mixture Cause Solution Possible Rich Fuel Mixture Cause Solution Fuel is very high octane Replace with lower octane fuel Stopping starting without adequate warm Allow engine to warm up before operat up ing and or stopping Clogged air filter Inspect and clean or replace Kinked or plugged fuel vent line Inspect and replace 120 TROUBLESHOOTING Engine Stops or Loses Power Possible Cause Out of fuel Kinked or plugged fuel vent line Water present in fuel Fouled or defective spark plug Worn or defective spark plug wires Incorrect spark plug gap or heat range Loose ignition connections Low battery voltage Incorrect fuel Clogged air filter Reverse speed limiter malfunction Electronic throttle control malfunction Other mechanical failure Overheated engine Engine Overheating Possible Cause Debris lodged in screen Plugged Radiator Solution Clean radiator screen and core Clean engine exterior See your Polaris dealer Solution Remove and clean the screen Pull on the top portion of the screen then remove the lower portion Use a garden hose to flush any debris
34. Nm Oil Change 1 Position the vehicle on a level surface 2 Remove the fill plug 3 Place a drain pan beneath the gearcase Remove the gearcase drain plug 3 located on the bottom right hand side 4 Drainthe oil Dispose of used oil properly 5 Clean and reinstall the drain plug Torque to 11 ft Ibs 15 Nm 6 Add 6 ounces 175 ml of Polaris Premium Demand Drive Hub Fluid 7 Reinstall the fill plug Torque to 8 10 ft Ibs 11 14 Nm 8 Check for leaks 87 MAINTENANCE Engine Cooling System Radiator Coolant Level To ensure that the coolant maintains its ability to protect the engine we recommend that the system be completely drained every two years and a fresh mixture of antifreeze and water added Polaris recommends the use of Polaris Premium 60 40 anti freeze coolant or a 50 50 mixture of high quality aluminum compatible anti freeze coolant and distilled water Polaris Premium 60 40 is already premixed and ready to use Do not dilute with water See page 117 for the part numbers of Polaris products NOTE Always follow the manufacturer s mixing recommendations for the freeze protection required in your area Any time the cooling system has been drained for maintenance or repair replace the coolant If the recovery bottle has run dry the level in the radiator should be inspected Add coolant as needed 4 WARNING Escaping steam can cause severe burns Never remove the pressure
35. OFF position Worklight Switch 4 The worklight switch controls a light located at the rear of the vehicle Use the rear light when additional light is needed for loading and unloading the vehicle Turn the rear worklight off when driving the ATV 36 CONTROLS 4 WARNING Operating an ATV with sticking or improperly operating throttle controls could cause an accident and lead to severe injury or death Never start or operate an ATV with a sticking or improperly operating throttle Always contact your dealer for service if throttle problems arise 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 Throttle Lever Engine speed and vehicle movement are controlled by pressing the throttle lever 1 The throttle lever is spring loaded Engine speed returns to idle when the lever is released This ATV is equipped with Polaris Electronic Throttle Control ETC which is designed to reduce the risk of a frozen or stuck throttle If the throttle cable should stick in an open position when the operator releases the throttle lever the engine will stop and power to the rear wheels will cease 4 WARNING The Electronic Throttle Control ETC stops the engine in the event of a throttle system malfunction and is provided for y
36. R CON TRACT NEGLIGENCE OR OTHER TORT OR OTHERWISE ALL IMPLIED WARRANTIES INCLUDING BUT NOT LIMITED TO ANY IM PLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICU LAR 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 workman ship This limited warranty does not cover damage due to accidents abuse or improper handling maintenance or use This limited warranty also does not cover any engine that has been structurally altered or any engine that has been used in racing competition This limited warranty also does not cover physical damage corrosion or defects caused by fire explosions or other similar causes beyond the control of Polaris If you have any questions regarding your warranty rights and responsibilities you should contact the Polaris Warranty Department at 1 763 417 8650 129 MAINTENANCE LOG Use the following chart to record periodic maintenance DATE MILES KM TECHNICIAN SERVICE PERFORMED COMMENTS 130 MAINTENANCE LOG DATE MILES KM TECHNICIAN SERVICE PERFORMED COMMENTS 131 INDEX A Accessories 110 Adjustments 11
37. Rider Safety Never operate at excessive speeds Travel at speeds appropriate for your skills your passenger s skills and operating conditions Never attempt wheelies jumps or other stunts Always inspect your ATV before each use to make sure it s in safe operating condition Always follow the inspection and maintenance procedures and schedules outlined in your owner s manual Always travel slowly and use extra caution when operating on unfa miliar terrain Be alert to changing terrain conditions Never operate on excessively rough slippery or loose terrain Always follow proper turning procedures as described in this manu al Practice turning at low speeds before attempting to turn at faster speeds Do not turn at excessive speeds Always have the ATV inspected by an authorized Polaris dealer if it s been involved in an accident Always be careful of skidding or sliding On slippery surfaces like ice travel slowly and use extra caution to reduce the chance of skid ding or sliding out of control Never operate on hills too steep for the ATV or for your abilities Never operate this ATV in TURF mode while operating on a hill or other irregular terrain See page 43 Always follow proper procedures for climbing hills Check the ter rain carefully before ascending a hill Never climb hills with exces sively slippery or loose surfaces Shift body weight uphill Never open the throttle suddenly or make sudden gear changes Never go o
38. S NO WARRANTY OR SERVICE BULLETIN COVERAGE ON THIS VEHICLE IF IT IS SOLD OUTSIDE THE COUNTRY OF THE SELLING DEALER S AUTHORIZED LOCATION This policy does not apply to vehicles that have received authorization for export from Polaris Industries Dealers may not give authorization for export You should consult an authorized dealer to determine this vehicle s warranty or service bulletin coverage if you have any ques tions This policy does not apply to vehicles registered to government offi cials or military personnel on assignment outside the country of the selling dealer s authorized location This policy does not apply to Safety Recalls How to Get Service In the Country where your vehicle was purchased Warranty or Service Bulletin repairs must be done by an authorized Polaris dealer If you move or are traveling within the country where your vehicle was purchased Warranty or Service Bulletin repairs may be requested from any authorized Polaris dealer who sells the same line as your vehicle Outside the Country where your vehicle was purchased If you are traveling temporarily outside the country where your vehicle was purchased you should take your vehicle to an authorized Polaris dealer You must show the dealer photo identification from the country of the selling dealer s authorized location as proof of residence Upon residence verification the servicing dealer will be authorized to per form the warranty repair If You Move
39. TIAL HAZARD Operating on excessively steep hills WHAT CAN HAPPEN The vehicle may overturn HOW TO AVOID THE HAZARD Never operate on hills too steep for the ATV or for your abilities Never operate the ATV on hills steeper than 15 27 SAFETY Rider Safety 4 WARNING 28 POTENTIAL HAZARD Climbing hills improperly WHAT CAN HAPPEN Improper hill climbing could cause loss of control or overturn HOW TO AVOID THE HAZARD Always follow proper procedures for climbing hills as described in the SS owner s manual See page 61 UC Always check the terrain carefully before ascending any hill Never climb hills with excessively slippery or loose surfaces Shift body weight uphill A passenger should also shift body weight uphill Never open the throttle suddenly while traveling uphill The ATV could 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 Never operate this ATV in TURF mode while operating on a hill or other irregular terrain See page 43 Switch the AWD switch out of TURF mode and into AWD mode when ascending a hill SAFETY Rider Safety 4 WARNING POTENTIAL HAZARD Traveling downhill improperly WHAT CAN HAPPEN Improperly descending a hill could cause loss of control or overturn HOW TO AVOID THE HAZARD Always follow proper procedures for traveling down hills as descri
40. TROLS Master Cylinder The brake fluid in the master cylinder 1 which is located on the left handlebar should be checked before each ride The fluid level can be seen through an indicator window 2 on the top of the master cylinder This eye will appear dark when the fluid level is full When fluid needs to be added the eye will be clear NOTE When checking the fluid level the ATV must be on level ground with the handlebars straight If the fluid level is low add DOT 3 brake fluid only See page 117 for the part numbers of Polaris products 4 WARNING After opening a bottle of brake fluid always discard any unused portion Never store or use a partial bottle 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 accident or severe injury 39 CONTROLS Parking Brake 4 WARNING Operating the ATV while the parking brake is engaged could result in an accident and serious injury or death Always check to be sure the parking brake is disengaged before operating Setting the Parking Brake 1 2 Place the transmission in PARK Squeeze and release the brake lever 1 two or three times then squeeze and hold Push the park brake lock 2 forward to engage the brake Release the brake lever To release the parking brake lock squeeze
41. Warranty Registration Form must be completed by your dealer and submitted to Polaris within ten days Upon receipt of this registration Polaris will record the registration for warranty No verification of registration will be sent to the purchaser as the copy of the Warranty Registration Form will be the warranty entitlement If you have not signed the original registration and received the customer copy please contact your dealer immediately NO WARRANTY COVERAGE WILL BE ALLOWED UNLESS YOUR ATV IS REGISTERED WITH POLARIS Initial dealer preparation and set up of your ATV is very important in ensuring trouble free operation Purchasing a machine in the crate or without proper dealer set up will void your warranty coverage 124 WARRANTY WARRANTY COVERAGE AND EXCLUSIONS LIMITATIONS OF WARRANTIES AND REMEDIES The Polaris limited warranty excludes any failures that are not caused by a defect in material or workmanship This warranty does not cover accidental damage normal wear and tear abuse or improper handling This warranty also does not cover any ATV that has been altered structurally modified neglected improperly maintained used for racing or used for purposes other than for which it was manufactured or for any damages which occur during trailer transit or as a result of unauthorized service or the use of unauthorized parts In addition this warranty does not cover physical damage to paint or finish stress cracks tearing or pun
42. also take great pride in our complete line of apparel parts and accessories available through our online store at www purepolaris com Have your accessories and clothing delivered right to your door POLARIS The Way Out Copyright 2005 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 discrepancies may result between the actual vehicle and the information presented in this publication Depictions and or procedures in this publication are intended for reference use only No liability can be accepted for omissions or inaccuracies Any reprinting or reuse of the depictions and or procedures contained within whether whole or in part is expressly prohibited Printed in U S A 2006 Sportsman X2 500 EFI Owner s Manual P N 9920361 2 TABLE OF CONTENTS VEHICLE IDENTIFICATION NUMBERS 5 SAFETY 6 CONTROLS i by pay ecwa x 36 FEATURES rset igs eet tenets 43 OPERATION 52 EMISSION CONTROL SYSTEMS 73 MAINTENANCE 74 ADJUSTMENTS 115 POLARIS PRODUCTS 117 TROUBLESHOOTING 118 SPECIFICATIONS 122 WARRANTY 124 MAINTENANCE LOG
43. and around the piston rings and ring lands coating the cylinder with a protective film of fresh oil If Polaris fuel system additive is not used the fuel tank fuel lines and injector should be completely drained of gasoline MAINTENANCE Cleaning and Storage Storage Tips Inspect and Lubricate Inspect all cables and lubricate Follow lubrication guidelines in the Maintenance Section of the service or owner s manual to completely grease and lubricate the entire vehicle with Polaris Premium All Season Grease Battery Maintenance Conventional Remove the battery and add distilled water to the proper level Do not use tap water which may contain minerals that reduce battery life Apply dielectric grease to the terminal bolts and terminals Charge the battery at 1 4 amps or less until the specific gravity of each cell is 1 265 or greater Store the battery in a cool dry place Charge can be maintained easily by using Polaris Battery Tender charger PN 2871076 or by charging about once a month to make up for normal self discharge Battery Tender can be left connected during the storage period and will automatically charge the battery if the voltage drops below a pre determined point Check the fluid level monthly Battery Maintenance Sealed Remove the battery and recharge it as outlined on page 108 Store the battery in a cool dry place Engine Anti Freeze Test engine coolant strength and change if necessary Coolant sho
44. and understand your owner s manual and all warnings before operating a Polaris ATV The following signal words and symbols appear in this manual and on your vehicle Your safety is involved when these words and symbols are used Become familiar with their meanings before reading the manual A A The safety alert symbol on your vehicle or in this manual alerts you to the potential for personal injury WARNING The safety alert warning indicates a potential hazard that may result in serious injury or death CAUTION The safety alert caution indicates a potential hazard that may result in minor personal injury or damage to the vehicle CAUTION A caution indicates a situation that may result in damage to the vehicle NOTE 14 A note will alert you to important information or instructions SAFETY Rider Safety 4 WARNING Serious injury or death can result if you do not follow these instructions and procedures which are outlined in further detail within your owner s manual Read this manual and all labels carefully and follow the operating procedures described Never operate an ATV without proper instruction Take a training course Purchasers of a new Polaris ATV and their eligible family members are entitled to take the ATV RiderCourse Contact ATV Enrollment Express at 800 887 2887 or visit www atvsafety org for information on enrollment in the ATV RiderCourse Never allow anyone under 16 years of
45. ation Use Polaris DOT brake fluid Do not overfill 90 MAINTENANCE Brakes 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 5 Check the security and surface condition of the disc NOTE Pads should be changed when worn to 3 64 1 cm 3 64 1 cm Auxiliary Brake The auxiliary brake system is intended to be used as a backup for the main brake system Should the main system fail the rear brake can be activated by depressing the foot pedal on the inside of the right footrest The hydraulic auxiliary brake system requires no adjustment NOTE Since this is a rear brake only it will not be as effective as the all wheel single lever system 91 MAINTENANCE Steering Assembly The steering assembly of the ATV should be checked periodically for loose nuts and bolts If loose nuts and bolts are found see your Polaris dealer for service before operating the vehicle Toe Alignment 4 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 Use the following procedure to check the toe alignment of the vehicle The recommended toe alignment is 1 8 to 1 4 toe out 1 Setthe handlebars in a straight ahead position NOTE The steering frog
46. ause an accident resulting in serious injury or death Maintain proper tire pressure as described on the decal on your ATV and in the owner s manual Always use original equipment size and type when replacing tires Make sure the wheels are installed properly Always replace tires when the tread depth measures 1 8 3 cm or less Tire Tread Depth Always replace tires when tread depth is worn to 1 8 3 cm or less See illustration 1 8 3 cm Front Wheel Hub Tightening Front wheel bearing tightness and spindle e S nut retention are critical component operations All service must be performed by your authorized Polaris dealer Wheel Removal Stop the engine Place the transmission in PARK Lock the parking brake Loosen the wheel nuts slightly Elevate the side of the vehicle by placing a suitable stand under the footrest frame Ro aS 5 Remove the wheel nuts and remove the wheel 94 MAINTENANCE Wheel Installation 4 WARNING Improperly installed wheels can adversely affect tire wear and vehicle handling which can result in serious injury or death Always ensure that all nuts are torqued to specification Do not service axle nuts that have a cotter pin installed See your Polaris dealer 1 Place the transmission in PARK Lock the parking brake 2 Placethe wheel on the wheel hub with the valve stem toward the outside and the rotation arrows on the tire pointing toward forward rotation
47. avy pulling When operating in rough terrain swamps mountains etc at low ground speeds High Range When basic operation is at speeds greater than 7 MPH 11 KPH When operating at high ground speeds 104 MAINTENANCE PVT System 4 amp WARNING Failure to comply with the instructions in this warning can result in severe injury or death Do not modify any component of the PVT system Doing so may reduce its strength so that a failure may occur at a high speed The PVT system has been precision balanced Any modification will cause the system to be out of balance creating vibration and additional loads on components The PVT system rotates at high speeds creating large amounts of force on clutch components Extensive engineering and testing has been conducted to ensure the safety of this product However as the owner you have the following responsibilities to make sure this system remains safe Always follow all recommended maintenance procedures See your dealer as outlined in the owner s manual This PVT system is intended for use on Polaris products only Do not install it in any other product Always make sure the PVT housing is securely in place during operation PVT Drying There may be some instances when water is accidently ingested into the PVT system Use the following instructions to dry it out before operating 1 Remove the drain plug and allow the water to drain Replace the drain plug 2 Start t
48. bed in the owner s manual See page 63 Always check the terrain carefully before descending a hill Never operate this ATV in TURF mode while operating on a hill or other irregular terrain See page 43 Always descend a hill with the transmission in forward gear Do not descend a hill with the transmission in neutral Shift body weight uphill A passenger should also shift body weight uphill 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 29 SAFETY Rider Safety 4 WARNING POTENTIAL HAZARD Improperly crossing hills and turning on hills WHAT CAN HAPPEN Improperly crossing or turning as hills could cause loss of control or overturn HOW TO AVOID THE HAZARD 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 Use extra caution when turning on any hill Do not cross a hillside with a passenger on board Avoid crossing the side of a steep hill When crossing the side of a hill Always follow proper procedures as described in the owner s manual Avoid hills with excessively slippery or loose surfaces Shift body weight uphill 30 SAFETY Rider Safety 4 WARNING POTENTIAL HAZARD Stalling rolling backwards or improperly dismounting while climbing a hill
49. can be used as an indicator of whether the handlebars are straight The frog should always point straight back from the steering post 2 Place stands 1 in front of the vehicle perpendicular to the rear tires See illustration 3 Tiean elastic string around the stands making sure the string just touches the side surface of the rear tires on each side of the vehicle and goes around the stands in 1 front of the vehicle 2 4 Measure the distance from the string to the rim at the front and rear of the front rim 3 Rear measurement should be 1 16 1 8 2 to 3 cm more than the front measurement NOTE f you discover improper alignment see your Polaris dealer for service 92 MAINTENANCE Side Panel Removal 1 Remove the seat 2 Grasp the rear of the side panel near the rear cab With a firm motion pull the panel outward to disengage the side panel from the grommet 3 Pull the panel downward and rearward to remove it from the ATV 4 Reinstall the side panel by reversing the removal procedure Footwell Removal 1 Remove the six screws 1 on the bottom of the footwell 2 Use a flat screwdriver or sidecutters to remove the four plastic rivets 2 securing the footwell to the fenders 3 Remove the footwell 93 MAINTENANCE 4 WARNING Operating your ATV with worn tires improperly inflated tires non standard tires or improperly installed tires will affect vehicle handling and could c
50. cturing of upholstery material corrosion or defects in parts components or the ATV due to fire explosions or any other cause beyond Polaris control This warranty does not cover the use of unauthorized lubricants chemicals or fuels that are not compatible with the ATV The exclusive remedy for breach of this warranty shall be at Polaris exclusive option repair or replacement of any defective materials or components or products THE REMEDIES SET FORTH IN THIS WARRANTY ARE THE ONLY REMEDIES AVAILABLE TO ANY PERSON FOR BREACH OF THIS WARRANTY POLARIS SHALL HAVE NO LIABILITY TO ANY PERSON FOR INCIDENTAL CONSEQUENTIAL OR SPECIAL DAMAGES OF ANY DESCRIPTION WHETHER ARISING OUT OF EXPRESS OR IMPLIED WARRANTY OR ANY OTHER CONTRACT NEGLIGENCE OR OTHER TORT OR OTHERWISE Some states do not permit the exclusion or limitation of incidental or consequential damages or implied warranties so the above limitations or exclusions may not apply to you if inconsistent with controlling state law 125 WARRANTY ALL IMPLIED WARRANTIES INCLUDING BUT NOT LIMITED TO THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE ARE LIMITED IN DURATION TO THE ABOVE SIX MONTH WARRANTY PERIOD POLARIS FURTHER DISCLAIMS ALL EXPRESS WARRANTIES NOT STATED IN THIS WARRANTY Some states do not allow limitations on how long an implied warranty lasts so the above limitation may not apply to you if inconsistent with controlling state law
51. ding quick sharp turns which can cause skids Correct a skid by turning the handlebars in the direction of the skid and shifting your body weight forward CAUTION Severe damage to drive train may occur if the AWD is engaged while the wheels are spinning Always allow the rear wheels to stop spinning before engaging AWD or engage AWD before wheels begin to lose traction WARNING Failure to exercise care when operating on slippery surfaces can result in loss of tire traction and cause loss of control accident and serious injury or death Never apply the brakes during a skid Do not operate on excessively slippery surfaces Always reduce speed and use additional caution OPERATION Driving Uphill Whenever traveling uphill follow these precautions Oy ON Bt rt Always travel straight uphill Avoid steep hills 15 maximum Keep both feet on the footrests Shift body weight uphill Proceed at a steady rate of speed and throttle opening Remain alert and be prepared to take emergency action This may include quick dismounting of the vehicle If the vehicle stalls while climbing a hill never back it down the hill Apply the hand brake If a passenger is on board ask the passenger to dismount Use the K turn to turn around See page 64 4 WARNING Braking and handling are greatly affected when operating in hilly terrain Improper procedure could cause loss of control or overturn and result in ser
52. e the transmission in neutral Lock the parking brake Prime the oil pump using the procedure on page 84 Then stop the engine and inspect for leaks Recheck the oil level on the dipstick and add oil as necessary to bring it to the recommended level on the dipstick Dispose of used filter and oil properly 83 MAINTENANCE Oil Change Oil Pump Priming This priming procedure must be performed whenever the oil hose connection between the oil tank and pump inlet has been disconnected 1 Clamp or pinch off the vent line 1 approximately 2 from the oil tank 2 between the end of the oil tank vent fitting and the vent line s pressure relief slit 3 2 Run the engine for 10 20 seconds 3 Remove the vent line clamp If the line is bled properly you should hear a rush of air indicating that the line is properly primed and ready for operation f you do not hear air the line has not bled and you ll need to repeat the priming procedure 84 MAINTENANCE Transmission Oil Always check and change the transmission oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 74 We recommend the use of Polaris Premium AGL Synthetic Gearcase Lubricant See page 117 for the part numbers of Polaris products Cil Check The transmission fill plug 1 is located on the left side of the ATV under the rear fender behind the wheel Position the vehicle on a level surface Remove the
53. ealed battery Read all instructions before proceeding with the installation of this battery The YUASA activated sealed battery is already filled with electrolyte and has been sealed and fully charged at the factory Do not ever pry the sealing strip off or add any other fluid to this battery The single most important thing to 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 108 MAINTENANCE Battery Battery Charging Sealed Battery For a refresh charge follow all instructions carefully 1 Check the battery voltage with a voltmeter or multimeter A fully charged battery will register 12 8 V or higher 2 Ifthe voltage is less than 12 8 volts recharge the battery NOTE When using an automatic charger refer to the charger manufacturer s instructions for recharging When using a constant current charger use the following guidelines for recharging 4 WARNING An overheated battery could 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 NOTE Always verify battery condition before and 1 2 hours after the end of charging State of Voltage Charge Time Charge Using constant current charger 2 standard amps specified on top of battery 10096 12 8 13 0 vo
54. eath Have an authorized Polaris dealer perform these services 75 MAINTENANCE Periodic Maintenance Chart Perform all services at whichever maintenance interval is reached first Maintenance Interval whichever comes first Calendar Miles Km Steering Pre Ride Make adjustments as need Pro Rid ed See Pre Ride Checklist Pene Pre Ride pape meme Front suspension Rear suspension lock out Air filter pre filter Daily Inspect clean often replace as needed Drain deposits when visible Check level daily change Daily coolant every 2 years E Daily Check operation apply dielectric grease if replacing Headlamp tail lamp worklight Air filter main element Recoil housing Weekly Monthly 100 160 Inspect periodically 20H Monthly 200 320 Check terminals clean test Weekly Inspect replace as needed Drain water as needed check often if operating in wet conditions Monthly 250 400 Inspect level change yearly Transmission oil Monthly 250 400 Inspect level change yearly Engine breather 25H Monthly 250 400 Inspect clean if needed filter if equipped m Ea fan s d iu a iu i t i ey Ld ea RB o SNNT tube H B 76 MAINTENANCE Periodic Maintenance Chart Maintenance Interval meus ose comes first Calendar Miles Km uc NNI 500 800 Lubricate all fittings
55. ed warranty for this vehicle Polaris warrants that this vehicle is 1 designed built and equipped to conform at the time of initial sale with the requirements of 40 CFR 1051 and 2 free from defects in materials and workmanship that may keep it from meeting these requirements The emissions warranty period for this vehicle begins on the date the vehicle is delivered to the original retail purchaser and ends 30 months 2 5 years after that date or after 5000 km 3100 miles whichever comes first This emission related warranty covers components whose failure would increase an en gine s emissions including electronic controls fuel injection exhaust gas recirculation aftertreatment or any other system utilized in this vehicle to control emissions Replac ing or repairing other components not covered by this emissions warranty or the standard warranty is the responsibility of the owner including the parts labor and other costs associated with recommended maintenance The exclusive remedy for breach of this limited warranty shall be at the exclusive option of Polaris repair or replacement of any defective materials components or 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 OTHE
56. ely Eyes Flush with water for 15 minutes and get prompt medical attention Batteries produce explosive gases Keep sparks flame cigarettes etc away Ventilate when charging or using in an enclosed space Always shield eyes when working near batteries KEEP OUT OF REACH OF CHILDREN 106 MAINTENANCE Battery Battery Removal 1 SNC 9 Disconnect the hold down strap holding the battery in position and remove battery cover On conventional batteries remove the battery vent tube Disconnect the black negative battery cable first Disconnect the red positive battery cable next Lift the battery out of the ATV Be careful not to tip a conventional battery sideways which could spill electrolyte 4 CAUTION If electrolyte spills immediately wash it off with a solution of one tablespoon baking soda and one cup water to prevent damage to the vehicle Battery Installation 1 2 Set the battery in the battery holder With conventional batteries install the battery vent tube sealed batteries do not have a vent tube NOTE The vent tube must be free of obstructions and securely OY Un de CB installed If not battery gases could accumulate and cause an explosion The tube should be routed away from the frame and body to prevent corrosion Avoid skin contact with electrolyte which can cause severe burns First connect and tighten the red positive cable Second connect and tighten the black negative
57. ents and 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 Always test the brakes after leaving water If necessary apply them several times to let friction dry out the pads 4 WARNING POTENTIAL HAZARD Operating this ATV with improper tires or with improper or uneven tire pressure WHAT CAN HAPPEN Use of improper tires or operation of the ATV with improper or uneven tire pressure could cause loss of control or accident HOW TO AVOID THE HAZARD Always use the size and type of tires specified for the ATV Always maintain proper tire pressure as specified 33 SAFETY Rider Safety 4 WARNING 34 POTENTIAL HAZARD Operating the ATV with improper modifications WHAT CAN HAPPEN Improper installation of accessories or modification of the ATV may cause changes in handling which could lead to an accident HOW TO AVOID THE HAZARD Never modify the ATV through improper installation or use of accessories All parts and accessories added to the vehicle must be genuine Polaris Industries Inc or equivalent components designed for use on this ATV and should be installed and used according to approved instructions See your authorized Polaris ATV dealer for more information WARNING POTENTIAL HAZARD Overloading the ATV or carrying towing cargo improperly WHAT CAN HAPPEN Overloading and towing can cause chan
58. er comes first Calendar Miles Km Clutches drive 100 H 12M 1000 1600 Inspect clean replace worn and driven parts Front wheel 100 H 12M 1000 1600 Inspect replace as needed bearings Brake ud 250045250 Spark arrestor 3000 4800 27 12080 Toe adjustment po Inspect periodically adjust when parts are replaced Heaaigntam __ Adhstas needed p Perform these procedures more often for vehicles subjected to severe use Emission Related Service m Have an authorized Polaris dealer perform these services 78 MAINTENANCE Lubrication Guide Check and lubricate all components at the intervals outlined in the Periodic Maintenance Chart beginning on page 74 Items not listed in the chart should be lubricated at the General Lubrication interval Lubrication Guide Key P More often under severe use Polaris Premium All Season Grease or grease conforming to NLGI No 2 such as Conoco Superlube M or Mobilegrease Special e Use Polaris Premium U Joint Lube every 500 miles before long periods of storage or after pressure washing or submerging e ue Engine Oil Polaris Premium 4 Synthetic See page 81 ow40 Brake Fluid DOT 3 Only See page 39 Transmission Oil Polaris Premium AGL Synthetic See page 85 Gearcase Lube Front Demand Drive Premium Demand Drive Hub See page 87 Unit Front Gearcase Fluid Front Prop Shaft Grease Grease fittings 3 pumps Yoke A maxim
59. estor could result in serious injury or death Do not perform service on the spark arrestor while the system is hot Exhaust system temperatures can reach 1000 F Allow components to cool sufficiently before proceeding 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 run the engine in an enclosed area Exhaust contains poisonous carbon monoxide gas Never go under the vehicle while it s inclined Remove the arrestor clean out plug 1 from the bottom of the muffler Place the transmission in PARK Start the engine Purge carbon from the system by momentarily revving the engine several times If carbon is expelled cover or plug the exhaust outlet 2 and rap on the pipe around the cleanout plug while revving the engine several more times If particles are still suspected to be in the muffler elevate the rear of the vehicle one foot higher than the front Lock the parking brake and block the wheels Make sure the vehicle is in PARK and repeat steps 3 and 4 until no more particles are expelled when the engine is revved Stop the engine and allow the arrestor to cool Reinstall the arrestor plug and remove the outlet cover or plug 103 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
60. f protective gear for safe riding A helmet can prevent a severe head injury Select an approved helmet that meets or exceeds your state s safety standards and bears either the Department of Transportation DOT label the American National Standards Institute label ANSI z90 1 or the Snell Memorial Foundation label A passenger s helmet should have a rigid chin guard 2 Eye Protection Do not depend on sunglasses for proper eye protection A pair of goggles or a helmet face shield offer the best protection for your eyes They should be kept clean and be of shatterproof design bearing the markings Z2 1 or VESC 8 3 Gloves Off road style gloves with knuckle pads are the best for comfort and protection 4 Boots The best footwear is a pair of strong over the calf boots with heels like moto cross boots 5 Clothing Always wear long sleeves and long pants to protect arms and legs Riding pants with kneepads and a Jersey with shoulder pads provide the best protection 13 SAFETY Rider Safety 4 WARNING Failure to follow the warnings contained in this manual can result in serious 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
61. fer to page 36 for additional information PESLARIS 1 Rider Information Center Speedometer needle in addition to showing vehicle speed the needle flashes when a warning condition exists 3 Speedometer CAUTION To prevent damage wash the ATV by hand or with a garden hose using mild soap Do not use alcohol to clean the instrument cluster Immediately clean off any gasoline that splashes on the instrument cluster Do not allow insect sprays to come into contact with the lens 46 FEATURES Instrument Cluster Rider Information Center The rider information center is located in the instrument cluster All segments will light up for 2 5 seconds at start up NOTE Ifthe instrument cluster fails to illuminate a battery over voltage may have occurred and the instrument cluster may have shut off to protect the cluster s electrical system If this occurs take the ATV to your Polaris dealer for proper diagnosis 1 Gear Indicator As the shift lever is moved this indicates the gear the transmission is in 3 4 5 6 H High Range L Low Range 7 N Neutral R Reverse 8 P Park 2 2 AWD Indicator This indicator illuminates when the electrical portion of the AWD system is enabled 3 Engine Hour Display Indicator 1 Service Interval Diagnostic Mode Indicator 5 Low Battery or Over Voltage This warning usually indicates that the ATV is being operated at an RPM too low to keep the battery charged A low batte
62. fill plug Add the recommended oil as needed to bring the level to the bottom of the fill plug hole threads 4 Reinstall the fill plug Torque to 20 25 ft Ibs 27 34 Nm ots 85 MAINTENANCE Transmission Oil Oil Change The transmission drain plug 2 is located on the right side of the gearcase on the right side of the ATV behind the wheel well 1 Remove the fill plug Remove the drain plug 2 Drain the oil into a drain pan Dispose of used oil properly 3 Clean and reinstall the drain plug Torque to 20 25 ft Ibs 27 34 Nm 4 Add 32 oz 948 ml of the recommended transmission oil to bring the level to the bottom of the fill plug 5 Reinstall the fill plug Torque to 20 25 ft Ibs 27 34 Nm 6 Check for leaks 86 MAINTENANCE Front Gearcase Oil Always check and change the front gearcase oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 66 Maintain the oil level even with the bottom of the fill hole threads 1 We recommend the use of Polaris Premium Demand Drive Hub Fluid Use of other oils may result in improper operation of components See page 117 for the part numbers of Polaris products Oil Check 1 Position the vehicle on a level surface 2 Remove the fill plug 2 View the oil level 3 Add the recommended gearcase oil as needed to bring the level to the bottom of the fill hole threads 4 Reinstall the fill plug Torque to 8 10 ft Ibs 11 14
63. from the radiator fins NOTE High pres sure washers can deform the radiator fins and reduce cooling efficiency 121 SPECIFICATIONS SPORTSMAN X2 500 EFI Capacity weight not to exceed 400 Ibs 181 kg Based on EU Directive 76 432 EC 122 SPECIFICATIONS SPORTSMAN X2 500 EFI Cui ATA 25 8 12 C p Headlight 1 Single Beam on Headlight Pod 50 w 2 Single Beam on Bumper 27 w Carlisle AT489 25 x 11 12 5 psi Clutching Chart Altitude Shift Drive Clutch Driven Clutch Helix Weight pring Spring Meters 0 1800 10 WH Blue Green White Yellow EBS Feet 0 6000 PN 5630710 PN 7041157 PN 7041635 PN 5131674 1800 3700 10 RH Blue Green White Yellow EBS 6000 12000 PN 5630709 PN 7041157 PN 7041635 PN 5131674 EBS models require no helix spring adjustment 123 WARRANTY LIMITED WARRANTY Polaris Sales Inc 2100 Highway 55 Medina MN 55340 gives a SIX MONTH LIMITED WARRANTY on all components of the Polaris All Terrain Vehicle ATV against defects in material or workmanship Polaris also gives a one year limited warranty on the final drive chain for failure due to defects This warranty covers the parts and labor charges for repair or replacement of defective parts which are covered by this warranty This warranty begins on the date of purchase This warranty is transferrable to another consumer during the warranty period through a Polaris dealer REGISTRATION At the time of sale the
64. ges in vehicle handling which could lead to loss of control or an accident HOW TO AVOID THE HAZARD Never exceed the stated load capacity for this ATV Make sure cargo is properly distributed and securely attached Reduce speed when carrying cargo or pulling a trailer Allow a greater distance for braking Always follow the instructions in the owner s manual for carrying cargo or pulling a trailer See page 70 Always follow the instructions in the owner s manual for operating with a passenger See page 58 SAFETY Rider Safety A A WARNING Leaving the keys in the ignition can lead to unauthorized use of the vehicle resulting in serious injury or death Always remove the ignition key when the vehicle is not in use WARNING After any overturn or accident have a qualified service dealer inspect the entire vehicle for possible damage including but not limited to brakes throttle and steering systems WARNING Safe operation of this rider active vehicle requires good judgement and physical skills Persons with cognitive or physical disabilities who operate this vehicle or ride as a passenger have an increased risk of overturn and loss of control which could result in severe injury or death Never secure a passenger to the vehicle or to the operator with a belt rope or similar device CAUTION Exhaust system components are very hot during and after use of the vehicle Hot components can cause serious burns and fire
65. he engine and shift the transmission into neutral Apply varying throttle for 10 15 seconds to expel the moisture and air dry the belt and clutches Do not hold the throttle wide open for more than 10 seconds 3 Allow the engine RPM to settle to idle speed then shift the transmission to the lowest available range 4 Test for belt slippage If the belt slips repeat the process 5 Take the vehicle to your dealer for service as soon as possible 105 MAINTENANCE Battery Your ATV may have either a sealed battery which requires little maintenance or a conventional battery A sealed battery can be identified by its flat covers on the top of the battery A conventional battery has six filler caps on the top of the battery Always keep battery terminals and connections free of corrosion If cleaning is necessary remove corrosion with a stiff wire brush Wash with a solution of one tablespoon baking soda and one cup water Rinse well with tap water and dry off with clean shop towels Coat the terminals with dielectric grease or petroleum jelly Be careful not to allow cleaning solution or tap water into a conventional battery 4 WARNING Battery electrolyte is poisonous It contains sulfuric acid Serious burns can result from contact with skin eyes or clothing Antidote External Flush with water Internal Drink large quantities of water or milk Follow with milk of magnesia beaten egg or vegetable oil Call physician immediat
66. in power and traction if too much throttle is applied Loss of control or forward flipover may result especially in AWD See Owner s Manual 7172564 ALL WHEEL DRIVE SWITCH Do not push switch to engage AWD if the rear wheels are spinning This may cause severe drive shaft and clutch damage See your Owner s Manual 7079780 DATE VIN THIS VEHICLE IS AN ALL TERRAIN VEHICLE AND IS NOT INTENDED FOR USE ON PUBLIC ROADS CE V HICULE EST UN V HICULE TOUT TERRAIN QUI N EST PAS DESTIN TRE UTILIS SUR LES CHEMINS PUBLICS PATENT NOTICE Mtd by Al Terrain Vehicle Division Polaris Industries Inc under one or more of the following patents Other patents pending U S Patents 4697665 5036039 5975624 6016943 6092877 6149540 6224134 6270106 6340186 0378080 0389440 0400143 Tirso Canadian Certification Decal TRAILER MAX WEIGHT 1225 LBS 557 KG ON LEVEL GROUND HITCH MAX VERTICAL WEIGHT 120 LBS 55KG 7174159 11 SAFETY Safety Training safety training is a top priority for Polaris When you purchased your new ATV your dealer instructed you on the authorized ATV RiderCourse available to you and your eligible family members This training is included in the purchase price of your ATV Polaris strongly encourages you and your eligible family members who will be riding ATV to take the ATV RiderCourse You were also provided with printed materials that explain safe operating
67. in the direction of the turn 4 Keep both feet on the footrests 5 Lean your upper body to the inside of the turn while supporting your weight on the outer footrest NOTE This technique alters the balance of traction between the rear wheels allowing the turn to be made smoothly 6 The same leaning technique should be used for turning in reverse NOTE Practice making turns at slow speeds before attempting to turn at faster speeds 4 WARNING Turning at sharp angles or at excessive speeds can result in vehicle overturn and lead to serious injury Avoid turning at sharp angles Never turn at high speeds 57 OPERATION Driving with a Passenger 1 58 Make sure the passenger is at least 12 years of age and is tall enough to comfortably reach the footrests and grab handles Make sure the passenger is wearing appropriate riding gear including an approved helmet with a rigid chin guard See page 13 Perform the pre ride inspection See page 54 Convert the seat for 2 up riding See page 44 Make sure the passenger seat lock out is functioning properly Lock the parking brake Mount the vehicle from the left side After the operator is seated the passenger should mount the vehicle from the left side Always make sure the brake is engaged to ensure the vehicle remains motionless whenever a passenger mounts or dismounts Allow a passenger to ride only in the approved passenger seat Do not carry m
68. ing oil level could indicate the accumulation of contaminants such as water or excess fuel in the bottom of the oil tank Water in the bottom of the tank can lead to engine damage and must be drained Water accumulation increases as outside temperature decreases See your Polaris dealer for engine heater kits which provide quicker warm ups and easier starting in colder weather 55 OPERATION Driving Procedures 1 Wear appropriate riding gear See page 13 2 Perform the pre ride inspection See page 54 3 Place the transmission in PARK 4 Lock the parking brake 5 Mount the vehicle from the left side 6 Sit upright with both feet on the footrests and both hands on the handlebars 7 Start the engine and allow it to warm up then shift the transmission into gear 8 Check your surroundings and determine your path of travel 9 Shift the transmission into gear 10 Release the parking brake 11 Slowly depress the throttle with your right thumb and begin driving 12 Drive slowly Practice maneuvering and using the throttle and brakes on level surfaces 56 OPERATION Making Turns Both rear wheels drive equally at all times except when operating in TURF mode This means that the outside wheel must travel a greater distance than the inside wheel when turning and the inside tire must slip traction slightly 1 Slow down 2 Never turn quickly when carrying a passenger or cargo 3 Steer
69. ingestion into the the engine RPM from idle to full throttle Repeat several PVT system times as required During this procedure the throttle should not be held at the full position for more than 10 seconds Clutch seals should be inspected for damage if repeated leaking occurs Clutch malfunction See your Polaris dealer Poor engine performance Check for fouled plug or foreign material in gas tank or fuellines See your dealer Slippage from failure to Always warm up the belt by operating below 30 mph for warm up belt one mile 5 miles or more when temperature is below freezing Wrong or missing belt Always use the recommended belt Improper break in Always break in a new belt and or clutch by avoiding aggressive or high speed operation during the first two full tanks of fuel 118 TROUBLESHOOTING Engine Doesn t Turn Over Possible Cause Solution Low battery voltage Recharge battery to 12 5 VDC Loose battery connections Check all connections and tighten Loose solenoid connections Check all connections and tighten Engine Turns Over Fails to Start Possible Cause Solution times for 5 seconds each then start Engine Backfires Possible Cause Solution Weak spark from spark plug Inspect clean and or replace spark plug Incorrect spark plug gap or heat range Set gap to specs or replace plug Old or non recommended fuel Replace with new fuel 119 TROUBLESHOOTING Engine Pings or Knocks Possible
70. ion Code Code E No RPM Signal Engine Temp Lamp Open Load 21 Loss of Synchronization 54 Engine Temp Lamp Short Circuit to Ground 45 Barometric Pressure Sensor 54 Engine Temp Lamp Short Circuit Circuit Low Input to Battery 46 Barometric Pressure Sensor 55 Diag Lamp Open Load Circuit High Input 22 TPS Open or Short Circuit to 55 Diag Lamp Short Circuit to Ground Ground 22 TPS Short Circuit to Battery 55 Diag Lamp Short Circuit to Battery RAM Error Defective ECU Pump Relay Open Load 42 Engine Temp Sensor Circuit 56 Pump Relay Short Circuit to Short to Ground Ground 42 Engine Temp Sensor Circuit 56 Pump Relay Short Circuit to Open or Short to Battery Battery 51 Injector 1 Open Load 41 Intake Air Temp Sensor Open or Short Circuit to Sensor Voltage Injector 1 Short Circuit to Ground Intake Air Temp Sensor Short Circuit to Ground 9 51 OPERATION Fuel Safety 4 WARNING 52 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 Never fill a gas container while it s in the cargo box Static elec tricity between the box and container could cause a spark Do not smoke or allow open flames or sparks in or near the area where refueling is performed or where gasoline is stored Do not overfill the tan
71. ious injury or death Avoid climbing steep hills 15 maximum Use extreme caution when operating on hills and follow proper operating procedures outlined in the owner s manual 61 OPERATION Driving on a Hillside 4 WARNING Improperly crossing hills or turning on hills can result in loss of control or vehicle overturn resulting in severe injury or death Avoid crossing the side of a hill when possible Do not cross a hillside with a passenger on board Follow proper procedures as outlined in the owner s manual Sidehilling can be the most dangerous type of driving encountered and should be avoided if at all possible If you do enter into a situation where sidehilling is necessary follow these precautions 1 Slow down 2 Do not cross a hillside with a passenger on board Ask the passenger to dismount and walk across the hillside before remounting the vehicle 3 Lean into the hill transferring your upper body weight toward the hill while keeping your feet on the footrests 4 Steer slightly into the hill to maintain vehicle direction NOTE Ifthe vehicle begins to tip quickly turn the front wheel downhill if possible or dismount on the uphill side immediately 62 OPERATION Driving Downhill Whenever descending a hill follow these precautions 1 PWN 3 Always descend a hill with the transmission in forward gear Do not descend a hill with the transmission in neutral Slow down P
72. k 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 Never start the engine or let it run in an enclosed area Engine exhaust fumes are poisonous and can cause loss of consciousness or death in a short time WARNING 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 OPERATION Break In Period The break in period for your new Polaris ATV is the first ten hours of operation or the time it takes to use the first two full tanks of gasoline No single action on your part is as important as following the 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 CAUTION Excessive heat build up during the first three hours of operation will damage close fitted engine parts and drive components Do not operate at full throttle or high speeds during the first three hours of use Engine and Drivetrain Break in 1 the fuel tank with gasoline See page 42 2 Check the oil reservoir level on the dipstick See page 81 Add oil if necessary to maintain the level between the safe and add marks 3 Drive slowly at first Select an open area that allows room to familiarize yourself with vehicle operation and
73. lamp from the wiring harness Use a small screwdriver to remove the o rings from the headlight mounting tabs Pull the headlight housing up to release it from the locking tabs Lift the adjusting knob up to remove it from the locking tabs Carefully pull the assembly up and out of the pod Reverse the steps to install the new housing and reassemble the pod NOTE The distance from the headlamp parting line to the end of the adjustment knob stop is 5 1 8 13 cm c IN 10 Adjust the headlight aim by turning the adjusting knob EM 518 2 13 99 MAINTENANCE Lights Lower Headlamp Removal Installation 1 Turn the back of the headlight harness 1 counterclockwise and pull the harness assembly C UA away from the headlight P assembly LS 2 Remove the headlamp and P install the new headlamp A AP 3 Reinstall the harness assembly X YW into the headlight assembly 1 iT 4 Turn the headlight harness clockwise to secure the headlamp Taillight Brakelight Worklight Lamp Replacement 1 Open the tailgate 2 Remove the two screws 1 near the tailgate latch 3 Grasp the entire taillight assembly and pull it away from the vehicle 4 Remove the harness connector from the back of the light assembly 5 Turn the lamp 2 counterclockwise to remove it 6 Apply dielectric grease to the socket and install the new lamp X A 7
74. long sleeved shirt or jacket and long pants 22 SAFETY Rider Safety 4 amp WARNING POTENTIAL HAZARD Riding the ATV after consuming alcohol or drugs WHAT CAN HAPPEN Consumption of alcohol and or drugs could seriously affect operator and passenger judgment Reaction time may be slower Balance and perception could be affected Consuming alcohol and or drugs before or while riding an ATV could result in an accident causing severe injury or death HOW TO AVOID THE HAZARD DO NOT drink alcohol or use drugs or medications before or while driving the ATV or riding as a passenger 4 WARNING POTENTIAL HAZARD Operating the ATV at excessive speeds WHAT CAN HAPPEN Excessive speed increases the operator s chance of losing control of the ATV which can result in an accident causing severe injury or death HOW TO AVOID THE HAZARD Never operate at excessive speeds Travel at speeds appropriate for your skills your passenger s skills and operating conditions 23 SAFETY Rider Safety 4 WARNING POTENTIAL HAZARD Attempting wheelies jumps and other stunts WHAT CAN HAPPEN Attempting stunts increases the chance of an accident including an overturn HOW TO AVOID THE HAZARD Never attempt wheelies jumps or other stunts Avoid exhibition driving 4 WARNING POTENTIAL HAZARD Failure to inspect the ATV before operating Failure to properly maintain the ATV WHAT CAN HAPPEN
75. lts None check at None required 3 mos from date of manufacture 5096 7596 12 0 12 5 volts Needs Charge 5 11 hours 2596 5096 11 5 12 0 volts Needs Charge At least 13 hours verify state of charge 096 2596 11 5 volts or less Needs Charge At least 20 hours 75 100 12 5 12 8 volts May need slight 3 6 hours charge if no charge given check in 3 months 109 MAINTENANCE Accessories Auxiliary power outlets provide 12V power for operating accessories such as hand held spot lights Accessory outlets are available for all models Polaris also has a wide range of additional accessories available for your ATV See your Polaris dealer Cleaning and Storage See page 117 for the part numbers of Polaris products Washing the ATV Keeping your ATV clean will not only improve its appearance but it can also extend the life of various components The best and safest way to clean your ATV is with a garden hose and a pail of mild soap and water Use a professional type washing mitten cleaning the upper body first and the lower parts last Rinse with water frequently and dry with a chamois to prevent water spots Avoid the use of harsh cleaners which can scratch the finish NOTE f warning and safety labels are damaged contact your Polaris dealer for free replacement CAUTION High water pressure may damage ATV components Polaris recommends washing the ATV by hand or with a garden hose using mild soap Certain products including in
76. maintenance and service in the Maintenance Log beginning on page 130 NOTE Service and adjustments are critical If you re not familiar with safe service and adjustment procedures have a qualified dealer perform these operations Maintenance intervals in the following chart are based upon average riding conditions and an average vehicle speed of approximately 10 miles per hour Vehicles subjected to severe use must be inspected and serviced more frequently Severe Use Definition Frequent immersion in mud water or sand Racing or race style high RPM use Prolonged low speed heavy load operation Extended idle Short trip cold weather operation Pay special attention to the oil level A rise in oil level during cold weather can indicate contaminants collecting in the oil sump or crankcase Change oil immediately if the oil level begins to rise Monitor the oil level and if it continues to rise discontinue use and determine the cause or see your dealer 74 MAINTENANCE Periodic Maintenance Chart Maintenance Chart Key gt Perform these procedures more frequently 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 m Have an authorized Polaris dealer perform these services 4 WARNING Improperly performing the procedures marked with a m could result in component failure and lead to serious injury or d
77. minimum marks 41 CONTROLS Automatic Transmission Gear Selector The transmission gear selector 1 is located on the right side of the vehicle H High Gear L Low Gear N Neutral R Reverse P Park CAUTION Shifting gears with the engine speed above idle or while the vehicle is moving could cause transmission damage To change gears stop the vehicle and with the engine idling move the lever to the desired gear Whenever the ATV is left unattended always place the transmission in PARK and lock the parking brake Belt Life To extend belt life use low forward gear in heavy pulling situations and when operating at less than seven miles per hour for extended periods of time Fuel Tank The fuel tank filler cap 1 is located directly below the handlebar Use either leaded or unleaded gasoline with a minimum pump octane number of 87 R M 2 octane Fuel Filter The in line fuel filter should be replaced by your dealer after every 200 hours of operation and any time the fuel becomes contaminated with dirt or debris Do not attempt to clean the fuel filter 42 FEATURES All Wheel Drive AWD System The AWD system is activated S by a switch 1 on the right x handlebar JE ED When the switch is on 2X4 2 Auge center position the ATV is 1 SMS in two wheel drive at all times and the differential is locked When the switch is on AWD left position the ATV is
78. mph 16 kph while towing a load on a level surface Vehicle speed should never exceed 5 mph 8 kph when towing loads in rough terrain while cornering or while ascending or descending a hill Do not obstruct the headlight when loading the front rack OPERATION Hauling Cargo Load Distribution Your ATV has been designed to carry or tow a certain amount of load Always read and understand the load distribution warnings listed on the warning labels and never exceed the specified weights Cargo weight should be mounted as low as possible When operating over rough or hilly terrain reduce speed and cargo to maintain stable driving conditions 1 Always load the cargo box with the load as far forward as possible 2 Always operate the vehicle with extreme caution whenever hauling or towing loads Balance handling and control may be affected 3 Slow down 4 Make sure the cargo box dump latch is securely latched before loading and operating Unintentional dumping will result if weight is placed in the rear of the box and the latch is not secured Maximum Towing Capacities Do not exceed the following maximum capacities when towing Avoid towing on inclines Towing Load Vertical Hitch Level Ground Weight Sportsman X2 1225 Ibs 556 kg 120 Ibs 54 4 kg 500 EFI Belt Life Use low forward gear when hauling or towing heavy cargo to extend belt life 71 OPERATION Hauling Cargo Dumping Cargo 1
79. n unfamiliar terrain WHAT CAN HAPPEN AU Unfamiliar terrain may contain hidden rocks ym bumps or holes that could cause loss of control or ee gt gt overturn Aj fe LY HOW TO AVOID THE HAZARD Travel slowly and use extra caution when operating on unfamiliar terrain Always be alert to changing terrain conditions 4 WARNING POTENTIAL HAZARD Failure to use extra caution when operating on excessively rough slippery or loose terrain WHAT CAN HAPPEN s Operating on excessively rough slippery or loose E terrain could cause loss of EA 1 traction or loss of control 2 which could result accident or overturn HOW TO AVOID THE HAZARD Do not operate on excessively rough slippery or loose terrain until you ve learned and practiced the skills necessary to control the ATV on such terrain Always use extra caution on rough slippery or loose terrain Never operate this ATV in TURF mode while driving on uneven loose or slippery terrain conditions See page 43 26 SAFETY Rider Safety 4 amp WARNING POTENTIAL HAZARD Turning improperly WHAT CAN HAPPEN Improper turns could cause loss of control and lead to a collision or overturn HOW TO AVOID THE HAZARD Always follow proper procedures for turning as described in the owner s manual Practice turning at slow speeds before attempting to turn at faster speeds Never turn at excessive speed 4 WARNING POTEN
80. nd do not make sudden throttle changes If your vehicle becomes immersed and it s impossible to take it to a dealer before starting it follow the steps described on page 102 Have the vehicle serviced by your dealer at the first opportunity 67 OPERATION Driving in Reverse Follow these precautions when operating in reverse 1 Always avoid backing downhill 2 Always check for obstacles or people behind the ATV before operating in reverse Be aware that a passenger can obstruct your view 3 When it s safe to proceed in reverse move slowly and avoid turning at sharp angles 4 When in reverse apply the brakes lightly for stopping 5 Never open the throttle suddenly while backing 4 WARNING Failure to use caution when operating in reverse can result in serious injury or death Before shifting into reverse always check for obstacles or people behind the vehicle When it s safe to proceed back slowly Do not use the override switch unless additional power is required for vehicle movement Use with caution Avoid backing on inclines and avoid turning at sharp angles NOTE Your Polaris ATV is equipped with a reverse speed limiter The override button should be used with caution as rearward vehicle speed is greatly increased Do not operate at wide open throttle Open the throttle just enough to maintain a desired speed CAUTION Excessive throttle operation while in the speed limit mode may cause fuel t
81. non recommended oil or incorrect throttle body adjustments Spark Plug Removal and Replacement 1 Remove the spark plug cap 2 Using the special wrench provided in the tool pouch rotate the spark plug counterclockwise to remove 3 Reverse the procedure for spark plug installation using the recommended spark plug Torque to 18 ft lbs 24 Nm 101 MAINTENANCE Vehicle Immersion CAUTION If your vehicle becomes immersed major engine damage can result if the machine is not thoroughly inspected Take the vehicle to your dealer before starting the engine If it s impossible to take your ATV to a dealer before starting it follow the steps outlined below 1 Move the ATV to dry land or at the very least to water below the footrests 2 Check the air box for any water and dry it if water is present NOTE Filter replacement is required if water is present Remove the spark plug Turn the engine over several times using the electric start Dry the spark plug and reinstall or replace it with a new plug ON MY AR Attempt to start the engine If necessary repeat the drying procedure 7 Take the ATV to your dealer for service as soon as possible whether you succeed in starting it or not NOTE f water has been ingested into the PVT follow the procedure on page 105 for drying out the PVT 102 MAINTENANCE Spark Arrestor 4 amp WARNING Failure to heed the following warnings while servicing the spark arr
82. nt 2870791 Fogging Oil 12 oz Aerosol 2871281 Premium 4 Synthetic OW 40 4 Cycle Engine Oil qt 2871844 Premium 4 Synthetic OW 40 4 Cycle Engine Oil gal Gearcase Transmission Lubricants 2873602 Premium AGL Synthetic Gearcase Lube qt 2873603 Premium AGL Synthetic Gearcase Lube gal 2871653 Premium ATV Angle Drive Fluid 8 oz 2872276 Premium ATV Angle Drive Fluid 2 5 gal 2870465 Pump for Gallon Jug 2871654 Premium Demand Drive Hub Fluid 8 oz 2872277 Premium Demand Drive Hub Fluid 2 5 gal Grease Specialized Lubricants 2871322 Premium All Season Grease 3 oz cartridge 2871423 Premium All Season Grease 14 oz cartridge 2871460 Starter Drive Grease 2871515 Premium U Joint Lube 3 oz 2871551 Premium U Joint Lube 14 oz 2871312 Grease Gun Kit 2871329 Dielectric Grease Nyogel 2872073 Chain Lube 6 25 oz aerosol 2872348 Chain Lube 16 oz aerosol Coolant 2871323 60 40 Coolant gal 2871534 60 40 Coolant qt Additives Miscellaneous 2872889 Brake and Clutch Cleaner 2871326 Carbon Clean Plus 12 oz 2870652 Fuel Stabilizer 16 oz 2870990 DOTS Brake Fluid 2872893 Engine Degreaser 2871956 LOCTITE 565 Thread Sealant 117 TROUBLESHOOTING Contact your Polaris dealer for service if you re unable to identify solutions using the following charts Drive Belt and Cover Problems Driving onto a pickup or Shift transmission to low range during loading of the ATV tall trailer in high range t
83. o build in the exhaust resulting in engine popping and or engine damage 68 OPERATION Driving Over Obstacles 1 Be alert Look ahead and learn to read the terrain you re traveling on Be constantly alert for hazards such as logs rocks y and low hanging branches Avoid operating ex over large obstacles such as rocks and fallen trees when possible If unavoidable use extreme caution EP kis Always have a passenger dismount before operating over an obstacle that could cause a fall from the vehicle or vehicle tipover 4 WARNING Severe injury or death can result if your vehicle comes in contact with a hidden obstacle Not all obstacles are immediately visible Travel with caution in unfamiliar terrain Parking on an Incline Avoid parking on an incline if possible If it s unavoidable follow these precautions 1 2 3 Turn the engine off Place the transmission acera in PARK 7 20 Lock the parking SA brake A Always block the rear i wheels on the downhill side as shown in the illustration 69 OPERATION Hauling Cargo A 70 WARNING Overloading the vehicle or carrying or towing cargo improperly can alter vehicle handling and may cause loss of control or brake instability Always follow these precautions when hauling cargo Never exceed the stated load capacity for this vehicle Never carry cargo in the rear box when operating the
84. o prevent belt burning Starting out going up a When starting out on an incline use low range or dis steep incline mount the ATV after first applying the park brake and perform the K turn as described on page 64 Driving at low RPM or Drive at a higher speed or use low range more frequently low ground speed at The use of low range is highly recommended for cooler approximately 3 7 MPH PVT operating temperatures and longer component life Insufficient warm up of Warm the engine at least 5 minutes With the transmission ATVs exposed to low am in neutral advance the throttle to about 1 8 throttle in bient temperatures Short bursts 5 to 7 times The belt will become more flex ible and prevent belt burning Slow easy clutch engage Use the throttle quickly and effectively ment Towing pushing at low Use low range only RPM low ground speed 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 Shift the transmission to low range and carefully use fast objects from a stopped brief aggressive throttle application to engage clutch position WARNING Excessive throttle may cause loss of control and vehicle overturn Belt slippage from water Shift the transmission to neutral Using the throttle vary or snow
85. ocates properly in the housing 8 Reassemble the pod 97 MAINTENANCE Lights High Beam Adjustment The headlight beam can be adjusted slightly upward or downward Use the following procedure to make the adjustment 1 Position the vehicle on a level surface with the headlight approximately 25 ft 7 6 m from a wall 2 Measure the distance from the floor to the center of the headlight and make a mark on the wall at the same height 3 Start the engine and 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 1 cm below the mark on the wall NOTE Include rider and passenger weight on the seat when measuring 5 The adjustment knob is located on the right side of the headlight pod Adjust the beam to the desired position by turning the knob either clockwise or counterclockwise Low Beam Adjustment The low beam can be adjusted slightly upward or downward 1 Loosen the phillips screw 1 located at the rear of the headlamp 2 Tilt the headlamp upward or downward 3 Tighten the screw 98 MAINTENANCE Lights Headlight Housing Replacement 1 Remove the two screws on the lower front corners of the headlight pod 2 Liftthe pod slightly while depressing the tabs at the rear of the pod 3 Lift the pod cover and disconnect the speedometer harnesses from the speedometer gt Unplug the head
86. on new machines is normal as the system is purging itself of trapped air Observe coolant levels and maintain as recommended by adding coolant to the recovery bottle 89 MAINTENANCE Brakes The front and rear brakes are hydraulic disc brakes activated by moving the single brake lever toward the handlebar These brakes are self adjusting 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 4 WARNING 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 accident or severe injury After opening a bottle of brake fluid always discard any unused portion 1 Always keep brake fluid at an adequate level see page 39 4 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 NOTE 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 Always fill the reservoir as needed whenever the cover is loosened or removed to ensure proper oper
87. on the movable drive sheave by the flyweights also increases This in turn increases the amount of pinch applied to the drive belt Similarly if the engine speed decreases the amount of centrifugal force decreases reducing the amount of belt pinch On Polaris ATVs the approximate gear ratio difference between high and low range is 1 2 25 This difference in gearing affects the operation of the PVT especially at speeds less than 7 MPH 11 KPH due to the system s dependence on engine speed For example when operating at a ground speed of 3 MPH 5 KPH in low range the engine speed would be around 3000 RPM This is well above the engagement speed of 1200 1400 RPM However in high range at 3 MPH 5 KPH 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 and causes outer clutch covers to fail By switching to low range while operating at low ground speeds the air temperature in the clutch cover is reduced by almost 160 degrees Reducing the temperature inside the clutch cover extends the life of the PVT components belt cover etc When To Use Low Range vs High Range Following is a guideline for when to use low range and high range Low Range When basic operation is at speeds less than 7 MPH 11 KPH For he
88. ore 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 Any modifications to the original equipment of the vehicle create a substantial safety hazard and increase the risk of bodily injury 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 NOTE The addition of certain accessories including but not limited to mowers blades tires sprayers or large racks may change the handling characteristics of the vehicle Use only Polaris approved accessories and familiarize yourself with their function and effect on the vehicle 18 SAFETY Rider Safety 4 amp WARNING POTENTIAL HAZARD Operating this ATV without proper instruction WHAT CAN HAPPEN The risk of an accident is greatly increased if the operator does not know how to operate the ATV properly in different situations and on different types of terrain HOW TO AVOID THE HAZARD Beginning and inexperienced operators should complete the ATV RiderCourse offered by Polaris through the SVIA They should then regularly practice the skills learned in the course and the operating techniques described in the Owner s Manual For more information about the ATV RiderCourse contact ATV Enrollment Express a
89. ore than one passenger Slow down Control may be more difficult with a passenger on board Allow more time and distance for braking OPERATION Driving with a Passenger 10 11 12 13 14 Ride to the ability of your passenger instead of to your own ability Avoid unexpected or aggressive maneuvers that could cause a passenger to fall from the vehicle Do not cross a hillside with a passenger on board See page 62 A passenger should always be seated in the passenger seat with both feet on the footrests and both hands on the passenger grab handles at all times The passenger should never hold on to the operator Never secure a passenger to the vehicle or to the operator with a belt rope or similar device Make sure the passenger understands the importance of active riding When hill climbing or performing maneuvers a passenger should shift body weight in the same manner in which the driver shifts body weight For example the passenger should lean to the inside of a turn along with the operator and should always lean uphill when climbing and descending hills 59 OPERATION Driving on Slippery Surfaces Whenever riding on slippery surfaces such as wet trails or loose gravel or during freezing weather follow these precautions 1 2 60 Slow down when entering slippery areas Engage AWD before wheels begin to lose traction Maintain a high level of alertness reading the trail and avoi
90. our safety Do not attempt to modify the ETC system or replace it with any after market throttle mechanisms 37 CONTROLS Light Switches The light switch is located on the left handlebar It s used to turn the lights on and off and to switch the lights from HI to LO NOTE The lights won t work unless the key is in the ON position and the shut off switch is in the RUN position 4 WARNING Operating the ATV on streets or roads especially in darkness could result in an accident and serious injury or death Your ATV is not equipped with highway approved lights It s designed for and must be used for off road use only Use caution and drive at reduced speeds in conditions of reduced visibility such as fog rain and darkness Brake Lever The front and rear brakes are applied by squeezing the brake lever 1 toward the handlebar The front and rear 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 4 WARNING Operating the ATV with a spongy brake lever can result in loss of braking which could cause an accident Never operate the ATV with a spongy feeling brake lever 38 CON
91. ow 3100 Once enabled the AWD remains enabled until the AWD switch is turned off If the switch is turned off while the front gearcase is moving it will not disengage until the rear wheels regain traction Engage the AWD switch before getting into conditions where front wheel drive may be needed If the rear wheels are spinning release the throttle before switching to AWD CAUTION Switching to AWD or from TURF to 2X4 while the rear wheels are spinning may cause severe drive shaft and gearcase damage Always switch to AWD or to TURF from 2X4 while the rear wheels have traction or are at rest Passenger Seat Always make sure the passenger seat lock out is functioning properly before operating with a passenger Do not operate the vehicle with the seat in the 2 up position when operating without a passenger Always return the seat to the 1 up position for single rider operation Never carry cargo in the rear box when operating the ATV in the 2 up mode with a passenger Seat Conversion 1 Make sure the cargo box dump lever A is securely latched 2 Liftthe latch B at the top of the operator backrest and tilt the backrest slightly forward 3 Pull the passenger seat backrest C upward from the bed of the cargo box 44 FEATURES Passenger Seat 4 Continue lifting the backrest latch while lowering the backrest to create the passenger seat D 5 Release the backrest latch and make sure the under
92. p Check operation apply Polaris dielec tric grease when lamp is replaced Brake light tail lamp Check operation apply Polaris dielec 100 tric grease when lamp is replaced Riding gear Wear helmet goggles protective clothing Coolant level if applicable Ensure proper level Coolant hoses if applicable Inspect for leaks 97 E 55 54 OPERATION Starting the Engine 4 amp WARNING Engine exhaust contains poisonous carbon monoxide and can cause loss of consciousness resulting in severe injury or death Never run an engine in an enclosed area Position the vehicle on a level surface Place the transmission in PARK Lock the parking brake Sit on the vehicle and turn the engine stop switch to RUN Es UO Es NOTE not press the throttle while starting the engine 5 Turn the ignition key past the ON position to engage the starter Activate the starter for a maximum of five seconds releasing the key when the vehicle 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 CAUTION 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 ris
93. pivots uc NNI cables etc Throttle Cable 500 800 Inspect adjust lubricate ETC Switch replace if necessary Throttle Body In 50H 500 800 Inspect duct for proper seal take Duct ing air leaks Drive belt 50H 500 800 Inspect adjust replace as needed Cooling system 50H 1000 1600 Inspect coolant strength seasonally pressure test system yearly Engine oil change 100 H 1000 1600 Perform a break in oil change at one month I Oil filter change 100 H 6M 1000 1600 Replace with oil change Oil tank vent hose 100 H 12M 1000 1600 Inspect routing condition if equipped 0 100 H 1000 1600 Inspect adjust Fuel system filter 100 H 12M 1000 1600 Check for leaks at tank cap lines filter pump replace lines every two years Radiator 100 H 12M 1000 1600 Inspect clean external if applicable surfaces Cooling hoses 100 H 12M 1000 1600 Inspect for leaks if applicable gt Evaine mous won 100011600 Exhaust muffler 100 H 12M 1000 1600 Inspect pipe H Spark plug 100 H 1000 1600 Inspect replace as needed Wiring 100 H 1000 1600 Inspect for wear routing security apply dielectric grease to connectors subjected to water mud etc Perform these procedures more often for vehicles subjected to severe use E Emission Related Service m Have an authorized Polaris dealer perform these services 77 MAINTENANCE Periodic Maintenance Chart Maintenance Interval whichev
94. r should not remount until the vehicle returns to firm level ground 65 OPERATION Driving Through Water Your ATV can operate through water with a maximum recommended depth equal to the bottom of the footrests 1 Follow these procedures when operating through water 1 Determine water depths and current before crossing 2 Choosea crossing where both banks have gradual inclines Proceed slowly avoiding rocks and obstacles if possible After crossing dry the brakes by applying light pressure to the lever until braking action is normal After running the vehicle in water it s critical to have it serviced as outlined in the maintenance chart See page 74 The following areas need special attention engine oil transmission oil front gearcase and all grease fittings 66 OPERATION Driving Through Water 4 CAUTION Major engine damage can result if the vehicle is not thoroughly inspected after operation in water Perform the services outlined in the maintenance chart If your vehicle becomes immersed or is operated in water that exceeds the footrest level take it to your dealer for service before starting the engine NOTE Avoid operating the vehicle through deep or fast flowing water If you cannot avoid water that exceeds the recommended maximum depth go slowly balance your weight carefully avoid sudden movements and maintain a slow and steady forward motion Do not make sudden turns or stops a
95. reen 1 Battery voltage Screen 2 Tachometer Screen 3 AWD diagnostic This gauge indicates whether or not current is flowing through the AWD coil only on models with switchable AWD Screen 4 Gear circuit diagnostic This screen displays the resistance value in ohms being read at the gear switch input of the gauge 49 FEATURES Instrument Cluster Rider Information Center Diagnostic Mode Screen 5 Programmable service interval The purpose of the programmable service interval is to provide the consumer and dealer with a convenient reminder for routine maintenance When your vehicle leaves the factory this feature is set at 50 hours You must enable the programmable service interval before it can be used Once the service interval mode is set with the hours when service is due the hours of actual engine operation are subtracted from the set hours until 0 is reached When the counter reaches 0 the wrench icon will flash quickly for 5 seconds each time the vehicle is started as a reminder that the periodic maintenance is due To set the hours press and hold the mode override button until the wrench icon flashes When it begins to flash release the button The setting will increase by one hour each time the button is pressed Pressing and holding the button will allow the numbers to escalate much faster When the desired time increment is displayed release the button and wait for the wrench to stop flashing When the wrench s
96. resulting in loss of control and possible serious personal injury or death Follow the adjustment procedures exactly or see your Polaris dealer for service 1 Locate handlebar bolts 1 by removing the upper headlight pod 2 Loosen the four 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 Ibs 14 17 Nm then torque the rear two bolts A gap of up to 1 8 will remain at the rear bolts 115 ADJUSTMENTS Throttle Body Idle RPM Idle RPM is preset by the manufacturer If the engine idle speed is not satisfactory please see your Polaris dealer for adjustment Throttle Cable Freeplay Throttle cable freeplay is adjusted at the handlebar 1 Locate the throttle cable adjuster on the fe handlebar X 54 2 Squeeze the end of the rubber boot 1 and slide it far enough to expose the end of the inline cable adjuster 2 3 Loosen the locknut 3 4 Rotate the boot to turn the adjuster until 1 16 to 1 8 freeplay is achieved at the thumb lever 1 p NOTE While adjusting freeplay be sure to flip the throttle lever back and forth 5 Tighten the locknut 6 Squeeze the end of the rubber boot and slide it over the cable adjuster to its original position 116 POLARIS PRODUCTS Part No Description Engine Lubrica
97. roceed directly downhill Shift body weight uphill Apply the brakes slightly to aid in slowing Familiarize yourself with operation of the auxiliary brake in the event loss of normal service brakes occurs 4 WARNING Excessive speed can cause loss of control and lead to serious injury or death Always operate slowly when traveling downhill 63 OPERATION Turning Around on a Hill If the vehicle stalls while climbing a hill never back it down the hill Use the K turn to turn around 64 OPERATION Turning Around on a Hill 1 Stop the vehicle 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 vehicle is pointing straight uphill NOTE f a passenger is on board ask the passenger to dismount first then the operator may dismount Staying uphill of the vehicle turn the handlebars full left While holding the service brake release the parking brake lock and slowly allow the vehicle to roll around to your right until it s pointing across the hill or slightly downward Lock the parking brake and remount the vehicle from the uphill side keeping body weight uphill Restart the engine with the transmission still in forward Release the parking brake and proceed slowly controlling speed with the service brake until the vehicle is on more level ground NOTE passenge
98. ry warning may also occur under normal operation if the machine is at idle and high electrical load lights cooling fan accessories is applied Driving at a higher RPM or connecting a battery charger will usually clear the warning 6 Odometer Tachometer Tripmeter Hour Meter 7 Fuel Gauge The segments of the fuel gauge show the level of fuel in the fuel tank When the last segment clears a low fuel warning is activated All segments will flash FUEL will display in the LCD and the speedometer needle will blink Refuel immediately 8 Check Engine Warning Indicator This indicator serves two purposes The word HOT displays if the engine overheats It also appears if an EFI related fault occurs Do not operate the ATV if this warning appears Serious engine damage could result 9 Mode Indicator B 47 FEATURES Instrument Cluster Rider Information Center The rider information center has 4 standard modes Mode 1 Odometer Mode 2 Tripmeter Mode 3 Total Service Hours Mode 4 Tachometer The reverse override button on the left handlebar is also the mode button NOTE If using the mode button to program the rider information center or to toggle through the options the machine cannot be in reverse Mode 1 Odometer The odometer records the miles traveled by the ATV Mode 2 Trip Meter The trip meter records the miles traveled by the ATV on each trip if it s reset before each trip To reset the trip
99. s when operating over obstacles as described in this manual Avoid operating the ATV through deep or fast flowing water If it s unavoidable travel slowly balance your weight carefully avoid sud den movements and 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 Test the brakes after leaving water If necessary apply them lightly several times to allow friction to dry out the pads Always check for obstacles or people behind the ATV before operat ing in reverse Be aware that a passenger can obstruct your view When it s safe to proceed in reverse move slowly and avoid turning at sharp angles Always use the size and type of tires specified for your ATV and always maintain proper tire pressure Never modify an ATV through improper installation or use of acces sories Never exceed the stated load capacity for your ATV Cargo must be properly distributed and securely attached Reduce speed and follow the instructions in this manual for carrying cargo or towing Allow a greater distance for braking FOR MORE INFORMATION ABOUT ATV SAFETY call the Consumer Product Safety Commission at 1 800 638 2772 or visit www cpsc gov visit www atvsafety org or call Polaris at 1 800 342 3764 17 SAFETY Rider Safety Equipment Modifications We are concerned for the safety of our customers and for the general public Theref
100. seat latch is fully engaged If the seat can be lifted repeat the procedure until the under seat latch engages 6 Lift the adjustment latch E at the top of the passenger A backrest Raise the backrest to the desired position Release the latch making sure it locks into one of the three operating positions NOTE The backrest must be moved out of the lowest position before it can be secured in the upright position The lowest position is for seat storage only Do not leave the backrest in the lowest position Always adjust the backrest to one of the three operating positions 7 Test the passenger seat lock out by attempting to release the cargo box dump lever A If the dump lever releases the seat is not secure Repeat the set up procedure NOTE Ifthe lock out is not working properly do not allow a passenger to ride the vehicle See your Polaris dealer for Service 8 To return the vehicle to 1 up operation reverse all steps Be sure to lower the passenger backrest to the lowest position before folding it down into the cargo box Make sure both backrests lock securely in place 45 FEATURES Instrument Cluster Your ATV is equipped with an instrument cluster that senses vehicle speed from the right front wheel The instrument cluster measures distance in miles or kilometers as well as hours of operation It also includes a reverse speed limiter function that limits the ATV s speed to approximately 7 9 mph Re
101. sect repellants and chemicals will damage plastic surfaces Do not allow these types of products to come into contact with the ATV If a high pressure water system is used exercise extreme caution to avoid damaging wheel bearings radiator transmission seals body panels brakes and warning labels Grease all zerk fittings immediately after washing and allow the vehicle to run for a while to evaporate any water that may have entered the engine or exhaust system Waxing the ATV Unless it has a special finish your ATV can be waxed with any non abrasive automotive paste wax Do not wax models that have a camouflage finish 110 MAINTENANCE Cleaning and Storage Storage Tips CAUTION 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 necessary repairs and then clean the ATV thoroughly with mild soap and warm water to remove all dirt and grime Don t use harsh detergents or high pressure washers Some detergents deteriorate rubber parts Use dish soap type cleaners only High pressure washers may force water past seals Stabilize the Fuel Fill the fuel tank Add Polaris Carbon Clean Fuel Treatment or Polaris Fuel Stabilizer Follow the instructions on the container for the recommended amount Carbon clean will also reduce the possibility of bacterial growth in the fuel system Allow 15
102. t 800 887 2887 or visit www atvsafety org 4 amp WARNING POTENTIAL HAZARD Failure to follow the age recommendations for this ATV WHAT CAN HAPPEN Severe injury and or death could occur if a child under the minimum age recommendation operates this ATV or rides as a passenger Even though a child may be within the recommended age group for operating some ATVs he she may not have the skills abilities or judgment needed to operate or ride on this ATV safely and could be susceptible to accident or injury HOW TO AVOID THE HAZARD No one under the age of 16 should operate this ATV Never allow anyone under 12 years of age to ride as a passenger on this 2 up ATV 19 SAFETY Rider Safety 4 WARNING 20 POTENTIAL HAZARD Operating with more than one passenger WHAT CAN HAPPEN Passengers affect balance and steering and increase the risk of losing control which can result in severe injury or death HOW TO AVOID THE HAZARD Never operate the 2 up ATV with more than one passenger WARNING POTENTIAL HAZARD Carrying a passenger in the cargo box WHAT CAN HAPPEN A passenger riding in the cargo box could fall from the vehicle unexpectedly or may contact moving components both of which can result in severe injury or death HOW TO AVOID THE HAZARD Never allow a passenger to ride in the cargo box SAFETY Rider Safety 4 amp WARNING POTENTIAL HAZARD Operating an ATV on paved surfaces including sidewalks
103. that this spark arrestor be installed and functional when the vehicle is operated on public lands Operation of off road vehicles on public lands in the U S A is regulated by 43 CFR 8343 Violations are subject to monetary penalties Federal regulations can be viewed online at Ww gpoaccess gov ecfr Crankcase Emission Control System This engine is equipped with a closed crankcase system Blow by gases are forced back to the combustion chamber by the intake system All exhaust gases exit through the exhaust system Exhaust Emission Control System Exhaust emissions are controlled by engine design An electronic fuel injection EFI system controls fuel delivery The engine and EFI components are set at the factory for optimal performance and are not adjustable The emissions label is located on the recoil cover or stator housing Electromagnetic Interference This spark ignition system complies with Canadian ICES 002 This vehicle complies with European directives 97 24 EC and 89 336 EEC 73 MAINTENANCE Periodic Maintenance Chart Careful periodic maintenance will help keep your vehicle in the safest most reliable condition Inspection adjustment and lubrication of important components are explained in the periodic maintenance chart Inspect clean lubricate adjust and replace parts as necessary When inspection reveals the need for replacement parts use genuine Polaris parts available from your Polaris dealer Record
104. tops blinking your service hours are set NOTE f you scroll past the intended number hold the button down until the count turns over to 0 You can then reset the number If the service interval is enabled on your ATV and you wish to turn it off toggle to the service interval mode Press and hold the mode button for approximately 7 seconds until the word OFF appears in the Rider Information Center Screen 6 Miles Kilometers toggle The display in the tripmeter and odometer can be changed to display either kilometers or miles The current display mode will be shown as KM or MP To change hold in the mode button until the letters flash then press and release the button once When the display stops flashing the mode has been set 50 FEATURES Instrument Cluster Rider Information Center Special EFI Diagnostic Mode The EFI diagnostic mode is for informational purposes only Please see your Polaris dealer for all major repairs To download blink codes failure codes from the EFI module 1 Place the transmission in PARK Turn the engine off and turn the key switch to the ON position 2 Turn the key switch off and on three times in less than five seconds then leave the switch on Any blink code numbers stored in the EFI module will display one at a time in the alphanumeric display The number 61 and the word END will display after all codes have been transmitted Blink Failure Description Blink Failure Descript
105. uld be replaced every two years Storage Area Covers Set the tire pressure and safely support the ATV with the tires 1 2 off the ground Be sure the storage area is well ventilated and cover the machine with a genuine Polaris ATV cover NOTE not use plastic or coated materials They do not allow enough ventilation to prevent condensation and may promote corrosion and oxidation 113 MAINTENANCE Transporting the ATV Follow these procedures when transporting the vehicle 1 114 Turn off the engine and remove the key to prevent loss during transporting Place the transmission in PARK Lock the parking brake Securely install the fuel cap oil cap and seat 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 LE zy 00 v d ADJUSTMENTS Camber and Caster The camber and caster are non adjustable Rear Spring The rear shock absorber spring is adjusted by rotating the adjuster 1 either clockwise or counterclockwise to increase or decrease spring tension NOTE Accessory springs are available through your Polaris dealer Handlebars The handlebars can be adjusted for rider preference 4 WARNING Improper adjustment of the handlebars or incorrect torquing of the adjuster block tightening bolts can cause limited steering or loosening of the handlebars
106. um Ball Joint p Grease Locate fitting and grease with grease gun Rear Bearing p Grease Locate fitting and grease Carrier C with grease gun 79 MAINTENANCE Premium 4 Synthetic Lubricant Polaris Premium 4 All Season synthetic engine oil has been specially formulated for use in Polaris 4 cycle engines It s a fully synthetic high performance multi viscosity oil designed to provide the ultimate in lubrication performance and protection NOTE See page 117 for the part numbers of Polaris products Premium 4 possesses unsurpassed film strength over the widest possible temperature range It resists viscosity and frictional breakdown in ambient temperatures from 40 F to 120 F 40 to 449 C Its exceptional frictional properties result in more efficient operation more power output and lower fuel consumption Although Polaris Premium 4 is the only oil recommended for use in this engine use of any API certified SH oil is allowable as long as it s OW 40 Oil may need to be changed more frequently if Polaris Premium 4 is not used Follow the manufacturer s recommendations for ambient temperature operation CAUTION Mixing brands or using a non recommended oil may cause serious engine damage We recommend the use of Polaris Premium 4 synthetic Oil or another OW 40 API certified SH oil Never substitute or mix oil brands 80 MAINTENANCE Oil Level The oil dipstick and fill tube 1 are located on the left side of
107. ver the top of a hill at high speed Switch the AWD switch out of TURF mode and into AWD mode when ascending a hill Always follow proper procedures for going downhill and for braking on hills Check the terrain carefully before you start down a hill Shift body weight uphill Never go down a hill at high speed Avoid going down a hill at an angle which would cause the vehicle to lean sharply to one side Travel straight down the hill when pos sible Always follow proper procedures for crossing the side of a hill Do not cross a hillside with a passenger on board Avoid hills with ex cessively slippery or loose surfaces Shift body weight uphill Nev er attempt to turn the ATV around on any hill until you ve mastered on level ground the turning technique outlined in this manual Avoid crossing the side of a steep hill when possible 16 SAFETY Rider Safety Always use proper procedures if you stall or roll backwards while climbing a hill To avoid stalling maintain a steady speed when climbing a hill If you stall or roll backwards follow the special procedure for braking described in this manual Always dismount on the uphill side or to either side if the ATV is pointed straight uphill Turn the ATV around and remount following the procedure described in this manual Always check for obstacles before operating in a new area Never attempt to operate over large obstacles such as rocks or fallen trees Always follow proper procedure
108. with caution To prevent loss of control never activate override button with open throttle When this vehicle is not in operation or unattended place shift in the park position 7173948 SAFETY Safety Decals and Locations A WARNING Improper vehicle use can result in SEVERE INJURY or DEATH ALWAYS USE NEVER USE NEVER CARRY NEVER USE AN APPROVED ON PUBLIC MORE THAN WITH DRUGS HELMET AND ROADS ONE OR ALCOHOL PROTECTIVE GEAR PASSENGER FOR OPERATOR AND PASSENGER NEVER operate without proper training or instruction at speeds too fast for your skills your passenger s skills or the conditions on public roads a collision can occur with another vehicle with more than one passenger passengers affect balance and steering and increase risk of losing control with a passenger under the age of 12 THE OPERATOR MUST ALWAYS use proper riding techniques to avoid vehicle overturns on hills and rough terrain and in turns avoid paved surfaces pavement may seriously affect handling and control reduce speed and use extra caution at all times when carrying a passenger have passenger dismount when conditions require make sure passenger reads and understands this label and passenger safety label LOCATE AND READ OWNER S MANUAL FOLLOW ALL INSTRUCTIONS AND WARNINGS IF OWNER S MANUAL IS MISSING CONTACT A POLARIS DEALER FOR A REPLACEMENT 1997 2000 7173889 SAFETY Safety Decals and Locations

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