Home

Polaris 525 IRS Offroad Vehicle User Manual

1. the top of the access door To i l 1 Open the front box cover s 2 Remove the access panel 2 See page 84 SIZES 3 Remove fuse box cover TT 4 Remove the suspect fuse from the fuse panel If the fuse is blown install a new fuse with the same amperage Fuse Box 5 Secure the fuse box cover and access panel Rema Re 6 Secure the front box cover COO OCEDEIC I 20h uk 204 20 20h w JO RELAY RELAY RELAY RELAY RELAY al 5 DA CE AI AIFA I J DoE k SPARE STC ig FUEL PUMP 10A ny CHASSIS p SPARE EPS OPT ACCESSORY DRIVE LIGHTS RELAY 20h ih 20k ny M SPARE 20A K 1 SHIM ih BUMPER FUEL FN iH LIGNIS PUMP aLa ntur TEAR OF j t RAT or ELA HELA gt Label inside the Fuse Box Cover 96 MAINTENANCE Lights High Beam Adjustment The headlight beam can be adjusted slightly upward or downward Use the following procedure to make the adjustment 1 Position the vehicle on a level surface with the headlight approximately 25 ft 7 6 m from a wall Place the transmission in PARK 2 Measure the distance from the floor to the center of the headlight and make a mark on the wall at the same height 3 Start the engine Turn the headlight switch to high beam 4 Observe the he
2. Number Description Engine Lubricant 2870791 Fogging Oil 12 oz Aerosol 2876244 PS 4 Full Synthetic 5W 50 4 Cycle Oil qt 95 1 2876245 PS 4 Full Synthetic 5W 50 4 Cycle Oil gal 3 8 I 2878920 PS 4 Extreme Duty Synthetic 10W 50 4 Cycle Oil qt 95 1 2878919 PS 4 Extreme Duty Synthetic 10W 50 4 Cycle Oil gal 3 8 l Gearcase Transmission Lubricants 2878068 Ero Synthetic Gearcase Lubricant amp Transmission Fluid qt 2878069 a Gearcase Lubricant amp Transmission Fluid 2877922 Demand Drive Plus Fluid qt 95 I 2877923 Demand Drive Plus Fluid gal 3 8 I 2870465 Pump for Gallon 3 8 I Jug Coolant 2871323 Polaris Antifreeze 60 40 Premix gal 3 8 I 2871534 Polaris Antifreeze 60 40 Premix qt 95 I Grease Specialized Lubricants 2871312 Grease Gun Kit Premium All Season 2871322 All Season Grease 3 0z 89 ml cartridge 2871423 All Season Grease 14 0z 414 ml cartridge 2871460 Premium Starter Grease 2871515 U Joint Grease 3 0z 89 ml cartridge 2871551 U Joint Grease 14 0z 414 ml cartridge 2871329 Dielectric Grease Nyogel Additives Miscellaneous 2871326 Carbon Clean 2870652 Fuel Stabilizer 2872189 DOT 4 Brake Fluid 2871956 Loctite 565 Thread Sealant 2859044 POLARIS Battery Tender Charger 126 SPECIFICATIONS SPORTSMAN FOREST 570 EFI EPS Maximum Weight Capacity 485 Ibs 220 kg operator cargo accessories Dry Weight 720 lb
3. 3 Remove the key 4 Reverse the procedure to unlock the steering A The handlebars are locked in the full left position when the steering is locked Always unlock the steering before starting the engine 25 FEATURES AND CONTROLS Fuel Tank Cap This vehicle is equipped with a digital Fuel Tank fuel gauge that will indicate a low fuel Cap Gear condition Refuel when the gauge Selector indicates a low fuel condition Always refuel with the engine stopped and outdoors or in a well ventilated area Refuel on a level surface Remove the fuel tank cap to add fuel to the fuel tank Use either leaded or unleaded gasoline with a minimum pump octane number of 87 R M 2 octane Do not use fuel with ethanol content greater than 10 percent such as E 85 fuel Automatic Transmission Gear Selector The transmission gear selector is located on the right side of the vehicle High Gear Low Gear Neutral Reverse Park To shift gears brake to a complete stop When the engine is idling move the lever to the desired gear NOTICE Shifting gears with the engine speed above idle or while the vehicle is moving could cause transmission damage Whenever the vehicle is left unattended always place the transmission in PARK The transmission is locked when it s in PARK Belt Life To extend belt life use low forward gear when pulling a heavy load at less than 11 km h for extended periods
4. 45 Driving Through Water 52 53 Driving Uphill 44 45 E Electromagnetic Interference 70 Electronic Power Steering 23 Engaging 4X4 0 27 Engine Break In 39 Engine Fogging 119 Engine Oili cener doce ase awg oa 76 Equipment Modifications 9 Error Codes Engine 35 Exhaust Emission Control System 70 Eye Protection oses ec cise rosenes 9 F Fluid Brake sg incciae seep dana 85 86 Coolants eede ersa snese 83 84 Demand Drive 82 Engine Oil 76 79 Transmission Oil 80 81 Fluid Change Demand Drive 82 Engine Ol es ie se reecs yes 78 79 Transmission 81 Fluid Level Demand Drive 82 Engine Ol ereiaro eireas TI Transmission 81 135 INDEX F Poot Brake i 4 dete ceeas 24 Footwell Removal 91 Fuel Recommendations 26 Fuel Tank Cap 2 06 5 26 Fuse Replacement 96 G Gauge Code Definitions 36 37 Gauge Digital Analog 28 35 Gear Selector ccc eee ensen 26 GLOVES 2 24 dey eedeh eE eects a 9 H Handlebar Adjustment 113 Hauling Cargo 56 57 Hazard Warning Switch 21 Headlight Lamp 98 Headlight Switch 21 Helmets wisi wegw cea cevek ees 8 High Beam Adjustment 97 High Beam Switc
5. For example when operating at a ground speed of 3 MPH 5 km h in low range the engine speed would be around 3000 RPM This is well above the engagement speed of 1200 1400 RPM However in high range at 3 MPH 5 km h the engine would be running at only 1500 RPM Whenever operating this close to the engagement speed the engine may be running at a speed too low to provide the pinch needed to prevent belt slip Belt slip is responsible for creating the excessive heat that destroys belts wears clutch components and causes outer clutch covers to fail The air temperature in the clutch cover is substantially reduced by using low range while operating at low ground speeds Reducing the temperature inside the clutch cover greatly extends the life of the PVT components belt cover etc 105 MAINTENANCE PVT System When to Use Low Range and High Range Condition Range to Use Operating at speeds less than 7 MPH 11 km h Low Towing heavy loads Low Operating in rough terrain Swamps mountains etc Low Operating at speeds greater than 7 MPH 11 km h High PVT Drying There may be some instances when water is accidently ingested into the PVT system Use the following instructions to dry it out before operating 1 Position the vehicle on a level surface 2 Remove the drain plug Allow the water to drain completely Reinstall the drain plug 3 Start the engine Place the transmission in PARK 4 Apply v
6. Out of fuel Refuel cycle key to ON position three times for 5 seconds each then start Clogged fuel filter Replace the filter Water is present in fuel Drain the fuel system and refuel Old or non recommended fuel Replace with fresh recommended fuel Fouled or defective spark plugs Inspect plugs and replace if necessary No spark to spark plug Inspect plugs verify stop switch is on Water or fuel in crankcase Immediately see your POLARIS dealer Low battery voltage Recharge the battery to 12 8 VDC Mechanical failure See your dealer Engine Backfires Possible Cause Weak spark from spark plug Solution Inspect clean and or replace spark plugs Incorrect spark plug gap or heat range Set gap to specs or replace plugs Old or non recommended fuel Replace with fresh recommended fuel Incorrectly installed spark plug wires See your dealer Incorrect ignition timing See your dealer Mechanical failure See your dealer Loose ignition connections Check all connections and tighten Water present in fuel Replace with fresh recommended fuel 123 TROUBLESHOOTING Engine Pings or Knocks Possible Cause Poor quality or low octane fuel Solution Replace with recommended fuel Incorrect ignition timing See your dealer Incorrect spark plug gap or heat range Set gap to specs or replace plugs Engi
7. authorized POLARIS dealer or visit the POLARIS web site at www polaris com 16 SAFETY Safety Labels and Locations Warning labels have been placed on the vehicle for your protection Read and follow the instructions on each label carefully If a label becomes illegible or comes off contact your POLARIS dealer to pur chase a replacement Replacement safety labels are provided by POLARIS at no charge The part number is printed on the label The following pages repeat the information found on each label A General Alert Multi Lingual Before you operate this vehicle read the owner s manual A Hill Operation Alert e Never operate this vehicle on HILLS steeper than 25 degrees lt lt 25 To prevent flip over on hilly terrain when going up or down use throttle and brakes gradually Hill Operation Alert 17 SAFETY Safety Labels and Locations No Passenger Warning Rack Warning Tire Pressure Clutch Cover Alert Load Alert A No Passenger Warning WARNING NEVER ride as a passenger Passengers can cause a loss of control resulting in SEVERE INJURY or DEATH A Tire Pressure Load Alert TIRE PRESSURE IN PSI KPa FRONT 5 34 5 REAR 5 34 5 MAXIMUM WEIGHT CAPACITY Gross Vehicle Weight INCLUDING MACHINE DRIVER AND CARGO IS 485 LBS 220 kg Read Owner s Manual for more detailed loading information A Clutch Cover Alert NO STEP A Rack Warning Front an
8. while the engine is warm or hot Always allow the engine to cool before removing the pressure cap Open the front box cover 2 Remove the access panel C gt screws Squeeze the outer edges of the panel inward to remove the panel 3 Remove the pressure cap 4 Using a funnel slowly add coolant through the radiator filler neck 566686 5 Reinstall the pressure cap Use of a non standard pressure cap will not allow the recovery system to function properly Contact your dealer for the correct replacement part Radiator Cap 6 Reinstall the access panel and secure the front box cover 84 MAINTENANCE Brake Fluid Check brake fluid levels for both brake systems before each ride Always maintain brake fluid at the recommended level Do not overfill The brakes should feel firm when they re applied Spongy or weak brakes may indicate a fluid leak or low fluid level A low fluid level may also mean that brake pads are worn and need to be replaced Do not operate the vehicle with spongy or weak brakes See your dealer for ser vice A Operating the vehicle with a spongy brake can result in loss of braking which could cause an accident Never operate the vehicle with spongy feeling brakes If the fluid level is low add DOT 4 brake fluid only See page 126 for the part numbers of POLARIS products A An over full master cylinder may cause brake drag or brake lock up which could resu
9. Main Key Switch 22 Mode Reverse Override Switch 20 Momentary High Beam Switch 22 Turn Signal 0 21 Winch Switch 04 2065 se46046 22 T Taillights 23 c 04 stare tent oe te dae 99 Throttle Body Adjustment 114 Throttle Cable Freeplay Adjustment 114 Throttle Lever 6 800 see eee 23 DVS sstaa view araneo ana 92 93 Tread Depth sce sisissi eae a leienae lt 92 Wheel Installation 93 Wheel Nut Torque 93 Wheel Removal 92 Toe Alignment 88 Towing Loads 57 Training 5 5 oesp sete deaeneecton ent y 8 Transmission enese ginaw 26 Transmission Oil 80 Transporting the ATV 121 Turn Signal Lamp Rear 99 Turn Signal Replacement Front 99 Turn Signal Switch 21 Turning Around ona Hill 48 49 Turning the Vehicle 43 V Vehicle Identification Numbers 6 Vehicle Immersion 102 VIN bes canes a bee Hees Hass 6 WwW Warning Symbols 4 Washing the Vehicle 115 116 Wheel Hub Tightening 92 Wheel Installation 93 Wheel Nut Torque Specifications 93 Wheel Removal 92 Winch Cable Care 66 Winch Maintenance Service Safety 69 Winch Operation 61 65 Winch Safety Precautions 58 60 Winch Shock Loading 67 68 137 Before you operate this vehi
10. Shift Type H L N R P Based on EU Directive 76 432 EC 127 SPECIFICATIONS SPORTSMAN FOREST 570 EFI EPS Gear Reduction Low 23 91 1 Gear Reduction Reverse 21 74 1 Gear Reduction Forward 9 75 1 Drive Ratio Front 3 82 1 Tires Pressure Front Off Road Style Deep Tread Design 25x8 12 5 psi 34 5 kPa Tires Pressure Rear Off Road Style Deep Tread Design 25x11 12 5 psi 34 5 kPa Brakes Front Rear Single Control Hydraulic Disc Brake Auxiliary Foot Activated Hydraulic Disc Brake Parking Hydraulic lock all wheel Mechanical Lock in Park Hitch Rear mounting for attachment of coupling devices Winch Front permanent installed winch with 2500 Ibs 1125 kg capacity Headlight 1 Single Beam on Headlight Pod 50 watt 2 Single Beam on Bumper 50 watt Taillights 8 26 watts Brake Light 26 9 watts Instrument Cluster LCD Clutching Chart Altitude Shift Drive Driven Helix Weight Clutch Clutch Spring Spring Meters 0 1800 25 52G Black Red EBS Feet 0 6000 PN 5632409 PN 7043594 PN 3234451 PN 3234356 Non EBS PN 5132344 1800 3700 25 48 Black Red EBS 6000 12000 PN 5632408 PN 7043594 PN 3234451 PN 3234356 Non EBS PN 5132344 EBS models require no helix spring adjustment 128 WARRANTY LIMITED WARRANTY POLARIS Sales Inc 2100 Highway 55 Medina MN 55340 POLARIS gives a SIX MONTH LIMITED WARRANT
11. TROUBLESHOOTING Engine Stops or Loses Power Possible Cause Out of fuel Solution Refuel cycle key to ON position three times for 5 seconds each then start Kinked or plugged fuel vent line Inspect and replace Water is present in fuel Replace with new fuel Fouled or defective spark plugs Inspect clean and or replace spark plugs Worn or defective spark plug wires See your dealer Incorrect spark plug gap or heat range Set gap to specs or replace plug Loose ignition connections Check all connections and tighten Low battery voltage Recharge the battery to 12 8 VDC Incorrect fuel Replace with fresh recommended fuel Clogged air filter Inspect and clean or replace Reverse speed limiter malfunction See your dealer Electronic throttle control malfunction See your dealer Other mechanical failure See your dealer Overheated engine Clean radiator screen and core clean engine exterior see your dealer Engine Overheating Possible Cause Debris lodged in screen Solution Remove and clean the screen Pull on the top portion of the screen then remove the lower portion Plugged Radiator Use a garden hose to flush any debris from the radiator fins NOTE High pressure washers can deform the radiator fins and reduce cooling efficiency 125 POLARIS PRODUCTS Part
12. Do not attempt to adjust tie rod alignment All tie rod adjustments should be performed by an authorized POLARIS dealer 1 Position the vehicle on a level surface 2 Place the handlebars in a straight ahead position 3 Tie a length of string between two stands as shown in the illustration Position the stands so that the string is flush with the side of the rear tire If available you may use a long straight edge instead of string 4 Measure the distance from the string to the rim at the front 1 and rear 2 of the front rim The rear measurement should be 1 16 1 8 2 3 mm more than the front measurement on each side of the vehicle to obtain the recommended 1 8 to 1 4 3 6 mm toe out alignment 5 Repeat the measurement procedure on the other side of the vehicle 6 If you discover improper alignment see your POLARIS dealer for service 88 MAINTENANCE Power Steering Unit If your model is equipped with power steering frequently clean the areas around and on the power steering unit to allow proper cooling Clean these areas thoroughly Steering 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 Seat Removal 1 Grasp one side of the seat near the rear edge 2 Pull upward abruptly
13. If a belt fails always clean away all debris when replacing the belt 39 OPERATION Pre Ride Checklist Failure to inspect and verify that the ATV is in safe operating condition before operating increases the risk of an accident Always inspect the ATV before each use to make sure it s in safe operating condition Item Remarks Page Foot brake Ensure proper operation 24 Hand brake lever travel Ensure proper operation 87 Brake fluid Ensure proper level 85 Front suspension Inspect lubricate if necessary 75 Rear suspension Inspect lubricate if necessary 75 Steering steering lock ADEK the steering ensure free oper 25 ation Tires Inspect condition and pressure 92 Wheels fasteners Inspect ensure fastener tightness He Frame nuts bolts fasteners Inspect ensure tightness Fuel and oil Ensure proper levels 26 Coolant level if applicable Ensure proper level pa Coolant hoses if applicable Inspect for leaks Throttle Ensure proper operation a Indicator lights switches Ensure operation 20 Engine stop switch Ensure proper operation 20 Mirrors Adjust for best side rear vision 22 Air filter pre filter Inspect clean 94 Air box sediment tube Drain deposits whenever visible Headlamp Check operation apply POLARIS 21 dielectric grease when lamp is 97 replaced Brake light taillight Check operation apply POLARIS 99 dielectric grease when lamp is replaced
14. Riding gear Wear approved helmet goggles and 8 protective clothing Winch if equipped Inspect cable and switch 58 69 40 OPERATION Starting the Engine A 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 1 Position the vehicle on a level surface outdoors or in a well ventilated area 2 Place the transmission in PARK Tip The starter interlock will prevent the engine from starting if the transmission is in gear and the brake Is not engaged 3 Sit on the vehicle and move the engine stop switch to RUN Do not press the throttle while starting the engine 5 Turn the ignition key past the PARKING Ni LIGHTS ON position to engage the 2D Ww starter Activate the starter for a maximum G of five seconds releasing the key when the engine starts 6 If the engine does not start release the starter and wait five seconds 7 Repeat steps 5 and 6 until the engine starts NOTICE Operating the vehicle immediately after starting could cause engine damage Allow the engine to warm up for several minutes before operating the vehicle Cold Weather Operation If the ATV is used year round check the oil level frequently A rising oil level could indicate the accumulation of contaminates such as water or excess fuel in the bottom of the crankcase Water in the bottom of the crankcase can lead to engine
15. aggressive throttle application to engage clutch WARNING Excessive throttle may cause loss of control and vehicle rollover Climbing over large objects from a stopped position Shift the transmission to low range and carefully use fast brief aggressive throttle application to engage clutch WARNING Excessive throttle may cause loss of control and vehicle rollover Belt slippage from water or snow ingestion into the PVT system Dry out the PVT See page 106 Inspect clutch seals for damage if repeated leaking occurs Clutch malfunction See your POLARIS dealer Poor engine performance Check for fouled plugs or foreign material in gas tank or fuel lines See your dealer Slippage from failure to warm up belt Always warm up the belt by operating below 30 MPH for one mile 5 miles or more when temperature is below freezing Wrong or missing belt Install the recommended belt Improper break in Always break in a new belt and or clutch See page 39 122 Engine Doesn t Turn Over Possible Cause Tripped circuit breaker or blown fuse TROUBLESHOOTING Solution Reset the breaker Replace fuse Low battery voltage Recharge the battery to 12 8 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
16. 16 km h Never exceed 8 km h when towing loads in rough terrain while cornering or while ascending or descend ing hills OPERATION Hauling Cargo Towing Loads Towing is approved OFF ROAD ONLY Operating this vehicle with a trailer on public roads is prohibited Do not exceed the maximum capac ities when towing Do not tow any trailer on a grade steeper than 15 Unbraked Trailer Towing Capacity is 1786 lbs 810 kg based on EU Directive 76 432 EC A Using an improper hitch or exceeding the Maximum maximum tongue weight capacity can 17cm result in serious damage to the vehicle and will void your warranty Never install a hitch longer than 17 cm Never install automotive accessories on your POLARIS vehicle Always install POLARIS approved or equivalent accessories designed for use on the vehicle 57 WINCH GUIDE These safety warnings and instructions apply if your vehicle came equipped with a winch or if you choose to add an accessory winch to your vehicle A WARNING Improper winch use can result in SEVERE INJURY or DEATH Always follow all winch instructions and warnings in this manual Your winch may have a cable made of either wire rope or specially designed synthetic rope The term winch cable will be used for either unless noted otherwise Winch Safety Precautions Read all sections of this manual Never use alcohol or drugs before or while operating the winch Never allow children u
17. can be repositioned to the new mid point of the winch cable Always release the tension on the winch cable before repositioning the damper D Avoid being directly in line with the winch cable whenever possible Also never permit others to stand near or in line with the winch cable during winch operation Never hook the winch cable back onto itself This will damage the winch cable and may result in winch cable failure Never use straps chains or other rigging items that are damaged or worn 63 WINCH GUIDE Winch Operation 11 The ONLY time a winch equipped vehicle should be moving when using the winch is when that vehicle itself is stuck The winch equipped vehicle should NEVER be in motion to shock load the winch cable in an attempt to move a second stuck vehicle See the Shock Loading section on page 67 For your safety always follow these guidelines when winching a vehicle free IO J K mmo Q0 p gt Release the winch clutch and spool out the necessary length of winch cable Align the winch cable as close as possible to the winching vehicle s centerline Attach the winch cable hook to the anchor point or the stuck vehicle s frame following instructions in this manual Re engage the clutch on the winch Slowly winch in the slack in the winch cable Select the proper vehicle gear to propel the stuck vehicle in the direction of winching Shift to the lowest gear available on the stuck vehicle
18. components some minor discrepancies may result between the actual vehicle and the information presented in this publication Depictions and or procedures in this publication are intended for reference use only No liability can be accepted for omissions or inaccuracies Any reprinting or reuse of the depictions and or procedures contained within whether whole or in part is expressly prohibited The original instructions for this vehicle are in English Other languages are provided as translations of the original instructions Printed in U S A 2014 SPORTSMAN FOREST 570 EFI EPS Owner s Manual P N 9924299 TABLE OF CONTENTS INGFOGUCHION 22 000025000808 e202 05e0 e60 4 DANGLY iia decd nade eeeueecee ene ee eees 8 Features and Controls 20 Operation co ccsteccactustaaseseceesease 38 Winch Guide ice tcee eb bescesaeee es 58 Emission Control Systems 70 Maintenance 00ee eee e eens 71 Troubleshooting 00000 cece ee eens 122 POLARIS Products 2 5 126 Specifications 0200eeeeeees 127 Warranty 2c ccnccccedesceetee cede scenes 129 Maintenance Log 133 NGGX eert enasna nnna anaa 135 INTRODUCTION The following signal words and symbols appear throughout 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 The safety alert symbol i
19. for comfort and protection Boots The best footwear is a pair of sturdy over the calf boots with low heels Clothing Always wear long sleeves and long pants to protect arms and legs Riding pants with kneepads and a jersey with shoulder pads provide the best protection Equipment Modifications We strongly recommend that consumers do not install on a POLARIS ATV any equipment that may increase the speed or power of the vehicle or make any other modifications to the vehicle for these purposes The warranty on your POLARIS ATV is terminated if any equipment has been added to the vehicle or if any modifications have been made to the vehicle that increase its speed or power The addition of certain accessories including but not limited to 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 SAFETY Operator Safety A WARNING Serious injury or death can result if you do not follow the instructions and procedures listed here and throughout this manual A Read and understand all warnings cautions and operating procedures in this manual and on the safety labels before operating the vehicle Never operate this vehicle without proper instruction Take a training course Beginners should receive training from a certified instructor Never permit others to operate th
20. receive information and notices regarding your vehicle If you purchase from a private party If you purchase a POLARIS product from a private party to be kept and used outside of the country in which the product was originally purchased all warranty coverage will be denied You must nonetheless register your product under your name and address with a local POLARIS dealer in your country to ensure that you receive safety information and notices regarding your product 131 WARRANTY EXPORTED PRODUCTS EXCEPT WHERE SPECIFICALLY REQUIRED BY LAW THERE IS NO WARRANTY OR SERVICE BULLETIN COVERAGE ON THIS PRODUCT IF IT IS SOLD OUTSIDE THE COUNTRY OF THE SELLING DEALER S AUTHORIZED LOCATION This policy does not apply to products that have received authorization for export from POLARIS Dealers may not give authorization for export You should consult an authorized dealer to determine this product s warranty or service coverage if you have any questions This policy does not apply to products registered to government officials or military personnel on assignment outside the country of the selling dealer s authorized location This policy does not apply to Safety Bulletins NOTICE If your product is registered outside of the country where it was purchased and you have not followed the procedure set above your product will no longer be eligible for warranty or service bulletin coverage of any kind other than safety bulletins Products r
21. recommended spark plugs can result in serious engine damage Always use POLARIS recommended spark plugs Plug Condition Torque Specification New Spark Plug 7 5 ft Ibs 10 Nm Previously Installed Spark Plug 7 5 ft lbs 10 Nm Spark Plug Inspection Spark plug condition is indicative of engine operation Check the spark plug firing end condition after the engine has been warmed up and the vehicle has been driven at higher speeds Immediately check the spark plug for correct color See page 101 CAUTION A hot exhaust system and engine can cause burns Wear protective gloves when removing a spark plug for inspection 1 Rotate the spark plug cap 1 4 turn and pull it off the spark plug 2 Using the special wrench provided in the tool pouch rotate the spark plug counter clockwise to remove it 3 Reverse the procedure for spark plug installation Torque to specification 100 MAINTENANCE Spark Plugs Spark Plug Inspection Normal Spark Plug The normal insulator tip is gray tan or light brown There will be few combustion deposits The electrodes are not burned or eroded This indicates the proper type and heat range for the engine and the service The tip should not be flaky and white A white insulator tip indicates overheating caused by use of an improper spark plug or incorrect fuel Wet Fouled Spark Plug The wet fouled insulator tip is black A damp oil film covers the firing end There may be a carb
22. slide while using the foot brake reduce brake pressure Hand Brake Lever The hand brake operates both front and rear brakes Squeeze the brake lever toward the han dlebar to apply the all wheel brakes If the rear wheels begin to skid or slide while using the brake reduce lever pressure A Aggressively applying the brakes when backing down a hill may cause rear tipover Aggressively applying the brakes while moving forward may cause the rear wheels to skid and result in loss of control Read this owner s manual and understand the operation of all brake systems on this vehicle Always use caution whenever applying the brakes 24 FEATURES AND CONTROLS Parking Brake Locking the Parking Brake 1 Place the transmission in PARK 2 Squeeze the brake lever toward the handlebar 3 Push the parking brake lock forward to engage the lock 4 Release the brake lever 5 To release the parking brake lock squeeze and release the brake lever A Operating the vehicle while the parking brake is engaged could result in an accident and serious injury or death Always release the parking brake lock before operating Steering Lock Lock the steering to prevent unauthor ized use or theft of the vehicle Tip Place the steering lock keys in a safe place The lock must be replaced if the keys are lost 1 Turn the handlebars to the full left position 2 Insert the steering lock key and turn it clockwise
23. style high RPM use e Prolonged low speed heavy load operation e Extended idle e Short trip cold weather operation Pay special attention to the oil level A rise in oil level during cold weather can indicate contaminants collecting in the oil sump or crankcase Change oil immediately if the oil level begins to rise Monitor the oil level and if it continues to rise discontinue use and determine the cause or see your dealer 71 MAINTENANCE Periodic Maintenance Chart Maintenance Chart Key Symbol Description gt Perform these operations more often for vehicles subjected to severe use D Have an authorized POLARIS dealer perform these services WARNING Improperly performing the procedures marked with a D could result in component failure and lead to serious injury or death Have an authorized POLARIS dealer perform these services Perform all services at whichever maintenance interval is reached first Item Maintenance Interval Remarks whichever comes first Hours Calendar Miles Km Steering Front suspension Rear suspension Tires Brake fluid level Pre Ride ve ey oats need ed See Pre Ride Checklist Brake lever travel on page 40 Brake system 7 Wheels fasteners 7 Frame fasteners x z Engine oil level z Winch if equipped See pages 58 69 gt
24. the winch drum Too much winch cable at one end of the winch drum can damage the winch and the winch cable B If stacking occurs stop winching Follow step 15 on page 65 to feed and rewind the cable evenly before continuing the winch operation Never winch up or down at sharp angles This can destabilize the winching vehicle and possibly cause it to move without warning Never attempt to winch loads that weigh more than the winch s rated capacity The winch motor may become hot during winch use If you winch for more than 45 seconds or if the winch stalls during operation stop winching and permit the winch to cool down for 10 minutes before using it again Never touch push pull or straddle the winch cable while winching a load Never let the winch cable run through your hands even if wearing heavy gloves Never release the clutch on the winch Ri when the winch cable is under load Never use the winch for lifting or transporting people 59 WINCH GUIDE Winch Safety Precautions 20 21 22 23 24 25 60 Never use the winch to hoist or suspend a vertical load Never immerse or submerse your winch in water Take your winch to your dealer for service if this occurs Always inspect your winch and winch cable before each use Never winch the hook fully into the winch This can cause damage to winch components Unplug the remote control from the vehicle when the winch is not in use to pr
25. use Please see your POLARIS dealer 120 MAINTENANCE Transporting the ATV Follow these procedures when transporting the vehicle 1 Stop the engine 2 Place the transmission in PARK 3 Secure the fuel cap oil cap and seat 4 Always tie the frame of the ATV to the transporting unit securely with suitable straps or rope Do not attach tie straps to the front A arm bolt pockets racks or handlebars Front 5 Remove the key to prevent loss during transporting Rear 121 TROUBLESHOOTING Drive Belt Wear Burn Possible Cause Solution Driving onto a pickup or tall trailer in high range Use low range during loading Starting out going up a steep incline Use low range or turn around using the K turn see page 48 Driving at low RPM or ground speed Drive at a higher speed or use low range more frequently See page 106 Insufficient warm up at low ambient temperatures Warm the engine at least 5 minutes With the transmission in neutral advance the throttle to about 1 8 throttle in short bursts 5 to 7 times The belt will become more flexible and prevent belt burning Slow easy clutch Use the throttle quickly and effectively engagement 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
26. 3 Never work on your winch without first disconnecting the battery connections to prevent accidental activation of the winch 4 For your safety always replace POLARIS winch parts including the cable with genuine POLARIS replacement parts available at your authorized POLARIS dealer 5 Some winch models use wire rope as the winch cable Other winches use a specially designed synthetic rope as the winch cable 6 Never replace a synthetic rope winch cable with a consumer grade polymer rope such as can be purchased in a hardware store Although they may look similar they are NOT alike A polymer rope not designed for winch use will stretch and store excessive energy when winching WARNING Failure of a stretched rope under winching conditions will release all of the stored energy This will increase the chances of SEVERE INJURY or DEATH 69 EMISSION CONTROL SYSTEMS Noise Emission Control System Do not modify the engine intake or exhaust components as doing so may affect compliance with governmental noise level requirements Spark Arrester Your POLARIS vehicle has a spark arrester that was designed for on road and off road operation It is required that this spark arrester remain installed and functional when the vehicle is operated 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
27. 600 Inspect replace as needed gt Wiring 100 H 12M 1000 1600 Inspect for wear routing security apply dielectric grease to connectors subjected to water mud etc D Clutches drive 100 H 12M 1000 1600 Inspect clean replace worn and driven parts D Front wheel 100 H 12M 1000 1600 Inspect replace as needed bearings D Brake fluid 200 H 24M 2000 3200 Change every two years Spark arrester 300 H 36 M 3000 4800 Clean out Idle speed Adjust as needed D Toe adjustment Inspect periodically adjust when parts are replaced Headlight aim Adjust as needed gt Perform these procedures more often for vehicles subjected to severe use D Have an authorized POLARIS dealer perform these services 74 MAINTENANCE Lubrication Guide Check and lubricate all components at the intervals outlined in the Periodic Maintenance Chart beginning on page 71 Items not listed in the chart should be lubricated at the General Lubrication interval The a arms and lower control arms are lubricated at the factory and no additional lubrication will be needed However if these components are subjected to severe use grease zerks have been provided for additional lubrication at the user s discretion Item Lube Capacity at Inspection Procedure Fluid Change Engine Oil PS 4 5W 50 2 qt 1 9 I Maintain level in safe range 4 Cycle Oil on dipstick See page 77 Brake Fluid DOT 4 Brake Fluid axs Maintain level between
28. Air filter pre filter Daily Inspect clean often replace as needed gt Air box sediment Daily 2 Drain deposits when visible tube Coolant Daily Check level daily change coolant every 2 years Power steering unit Daily Inspect daily clean often if equipped Headlight taillight Daily Check operation apply worklight dielectric grease if replacing lamps gt Perform these procedures more often for vehicles subjected to severe use D Have an authorized POLARIS dealer perform these services 72 Periodic Maintenance Chart MAINTENANCE Item Maintenance Interval Remarks whichever comes first Hours Calendar Miles Km gt Air filter main Weekly Inspect replace as needed element Recoil housing gt Weekly Drain water as needed check often if operating in wet conditions gt Brake pad wear 10H Monthly 100 160 Inspect periodically D Battery 20H Monthly 200 320 Check terminals clean test gt Engine breather 25H Monthly 250 400 Inspect clean if needed valve if equipped gt Engine oil change 25H 1M 250 400 Break in oil and filter change gt Demand drive fluid 25 H 1M 250 400 Break in oil level check gt Rear gearcase oil 25H 1M 250 400 Break in oil level check gt Transmission oil 25H 1M 250 400 Break in oil level check gt General lubrication 50H 3M 500 800 Lubricate all fittings pivo
29. POLARIS Sportsman Forest 570 Owner s Manual for Maintenance and Safety Read this manual carefully It contains important safety information This is an adult vehicle only Operation is prohibited for those under 16 years of age WELCOME Thank you for purchasing a POLARIS vehicle and welcome to our world wide family of POLARIS enthusiasts Be sure to visit us online at www polaris com for the latest news new product introductions upcoming events career opportunities and more Here at POLARIS we proudly produce an exciting line of utility and recreational products e Snowmobiles e All terrain vehicles ATVs e Low emission vehicles LEVs e RANGER utility vehicles e RZR sport vehicles e VICTORY motorcycles e GEM vehicles Always follow the instructions and recommendations in this manual The 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 Please see your dealer for all of your service needs during and after the warranty period POLARIS POLARIS and SPORTSMAN are registered trademarks of POLARIS Industries Inc Copyright 2013 POLARIS Sales Inc All information contained within this publication is based on the latest product information at the time of publication Due to constant improvements in the design and quality of production
30. RANTY ARE THE ONLY REMEDIES AVAILABLE TO ANY PERSON FOR BREACH OF THIS WARRANTY POLARIS SHALL HAVE NO LIABILITY TO ANY PERSON FOR INCIDENTAL CONSEQUENTIAL OR SPECIAL DAMAGES OF ANY DESCRIPTION WHETHER ARISING OUT OF EXPRESS OR IMPLIED WARRANTY OR ANY OTHER CONTRACT NEGLIGENCE OR OTHER TORT OR OTHERWISE THIS EXCLUSION OF CONSEQUENTAL INCIDENTAL AND SPECIAL DAMAGES IS INDEPENDENT FROM AND SHALL SURVIVE ANY FINDING THAT THE EXCLUSIVE REMEDY FAILED OF ITS ESSENTIAL PURPOSE THE IMPLIED WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE IS EXCLUDED FROM THIS LIMITED WARRANTY ALL OTHER IMPLIED WARRANTIES INCLUDING BUT NOT LIMITED TO THE IMPLIED WARRANTY OF MERCHANTABILITY ARE LIMITED IN DURATION TO THE ABOVE SIX MONTH WARRANTY PERIOD POLARIS DISCLAIMS ALL EXPRESS WARRANTIES NOT STATED IN THIS WARRANTY SOME STATES DO NOT PERMIT THE EXCLUSION OR LIMITATION OF INCIDENTAL OR CONSEQUENTIAL DAMAGES OR ALLOW LIMITATIONS ON THE DURATION OF IMPLIED WARRANTIES SO THE ABOVE LIMITATIONS MAY NOT APPLY TO YOU IF INCONSISTENT WITH CONTROLLING STATE LAW 130 WARRANTY HOW TO OBTAIN WARRANTY SERVICE If your vehicle requires warranty service you must take it to a POLARIS Servicing Dealer When requesting warranty service you must present your copy of the Warranty Registration From to the dealer THE COST OF TRANSPORTATION TO AND FROM THE DEALER IS YOUR RESPONSIBILITY POLARIS suggests that you use your original selling dealer however you may use any POLA
31. RIS Servicing Dealer to perform warranty service In the country where your product was purchased Warranty or Service Bulletin repairs must be done by an authorized POLARIS dealer If you move or are traveling within the country where your product was purchased Warranty and Service Bulletin repairs may be requested from any authorized POLARIS dealer that sells the same line as your product Outside the country where your product was purchased If you are traveling temporarily outside the country where your product was purchased you should take your product to an authorized POLARIS dealer You must show the dealer photo identification from the country of the selling dealer s authorized location as proof of residence Upon residence verification the servicing dealer will be authorized to perform the warranty repair If you move If you move to another country be sure to contact POLARIS Customer Assistance and the customs department of the destination country before you move Product importation rules vary considerably from country to country You may be required to present documentation of your move to POLARIS in order to continue your warranty coverage You may also be required to obtain documentation from POLARIS in order to register your product in your new country You should warranty register your product at a local POLARIS dealer in your new country immediately after you move to continue your warranty coverage and to ensure that you
32. Slowly and carefully apply vehicle throttle and winch together to free the vehicle Stop winching as soon as the stuck vehicle is able to propel itself without the help of the winch Detach the winch cable hook Rewind the winch cable evenly back onto the winch drum following the instructions in this manual 12 Never attempt to winch another stuck vehicle by attaching the winch cable to a suspension component brush guard bumper or cargo rack Vehicle damage may result Instead attach the winch to a strong portion of the vehicle frame or hitch 64 WINCH GUIDE Winch Operation 13 Extensive winching will run down the battery on the winching vehicle Let the winching vehicle s engine run while operating the winch to prevent the battery from running low if winching for long periods 14 The winch motor may become hot during winch use If you winch for more than 45 seconds or if the winch stalls during operation stop winching and permit the winch to cool down for 10 minutes before using it again 15 After winching is complete especially if winching at an angle it may be necessary to re distribute the winch cable across the winch drum You will need an assistant to perform this task Release the clutch on the winch Feed out the winch cable that is unevenly bunched up in one area Re engage the winch clutch Have an assistant pull the winch cable tightly with about 100 Ibs 45 kg of tension using the hook strap Slow
33. Turn the key to the OFF position Odometer Mode The odometer records and displays the distance traveled by the ATV Trip Meter Mode The trip meter records the distance traveled by the ATV if reset before each trip To reset select the trip meter mode Press and hold the MODE button until the meter resets to zero In the Rider Information Center the trip meter display contains a decimal point but the odometer displays without a decimal point Hour Meter Mode This mode logs the total hours the engine has been in operation 33 FEATURES AND CONTROLS Instrument Cluster Digital Analog Gauge Rider Information Center Programmable Service Interval When the hours of engine operation equal the programmed service interval setting the wrench icon will flash for 5 seconds each time the engine is started When this feature is enabled it provides a convenient reminder to perform routine maintenance The service interval is programmed at 50 hours at the factory Use the following procedure to change the service interval 1 Press the MODE button until remaining service hours display 2 Press and hold the MODE button 3 When the service hours flash press and release the MODE button to advance the hours to the desired setting including OFF Press and hold the MODE button to set the new service hour interval Diagnostic Display Mode The EFI diagnostic display mode is for informational purposes only Please see your POLARIS dealer fo
34. View the fluid level in the master cylinder 4 Maintain the fluid level between the minimum and maximum marks Do not overfill 86 Foot Brake Fluid Reservoir MAINTENANCE Brakes The front and rear brakes are hydraulic disc brakes activated by apply ing the foot brake The handlebar brake is also hydraulic Both brake systems are self adjusting Brake Inspections Perform the following checks to keep the brake systems in good operat ing condition Check more often if brakes are used heavily under normal operation 1 Always keep brake fluid at an adequate level See page 85 2 Check the brake systems regularly for fluid leaks 3 Check the brakes for excessive travel or spongy feel 4 Check the friction pads for wear damage and looseness Replace the pads when the friction material is worn to mm 1mm 5 Check the security and surface condition of the disc Clean any grease using a recommended brake cleaner or alcohol Do not use spray lubricants or other petroleum based prod ucts If you discover any damage cracks excessive corrosion warping see your dealer for service before operating 87 MAINTENANCE Toe Alignment Use the following procedure to check the toe alignment of the vehicle The recommended toe alignment is 1 8 to 1 4 3 6 mm toe out WARNING Severe injury or death can result from improper toe alignment and adjustment
35. Y on all components of your POLARIS vehicle against defects in material or workmanship POLARIS further warrants that the spark arrestor in this product will meet the efficiency requirements of USFS standard 5100 1C for at least 1000 hours when subjected to normal use and when maintenance and installation are in accordance with POLARIS recommendations This warranty covers parts and labor charges for repair or replacement of defective parts and begins on the date of purchase by the original retail purchaser This warranty is transferable to another owner during the warranty period through a POLARIS dealer but any such transfer will not extend the original term of the warranty The duration of this warranty may vary by international region based upon local laws and regulations REGISTRATION At the time of sale the Warranty Registration Form must be completed by your dealer and submitted to POLARIS within ten days of purchase Upon receipt of this registration POLARIS will record the registration for warranty No verification of registration will be sent to the purchaser as the copy of the Warranty Registration Form will be your proof of warranty coverage If you have not signed the original registration and received the customer copy please contact your dealer immediately NO WARRANTY COVERAGE WILL BE ALLOWED UNLESS YOUR VEHICLE IS REGISTERED WITH POLARIS Initial dealer preparation and set up of your vehicle is very important in ensuring trouble f
36. adlight aim on the wall The most intense part of the headlight beam should be two inches 5 cm below the mark on the wall Include rider weight on the seat when measuring 5 The adjustment knob is located on the right side of the headlight pod Adjust the beam to the desired position by turning the knob either clockwise or counter clockwise Low Beam Adjustment 7 The low beam can be adjusted slightly A upward or downward lS N 1 Loosen the Phillips screw located at the rear of the headlamp _ 2 Tilt the headlamp upward or iy downward j oe crew 3 Tighten the screw LS 97 MAINTENANCE Lights A Poor lighting can result in loss of control or an accident Lights become dirty during normal operation Wash the headlights and taillights frequently Hot components can cause serious burns to skin Do not service the headlamps until they ve cooled Headlight Parking Light Lamp Replacement When servicing a halogen lamp do not 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 Hold the plastic part of the lamp 1 Place the transmission in PARK Parking Light E 2 Reach under the front bumper area to locate the lighting connectors 3 Parking Light Lamp Disconnect the harness connector Turn the socket counter clockwise 1 8 turn and remove the lamp assembly Pull the lamp straight out to remove it from the socket Headlam
37. and when operating uphill at a slow speed vAaAr S 26 FEATURES AND CONTROLS All Wheel Drive System The All Wheel Drive system is controlled by the 4X4 switch 4X4 Mode When the switch is on 4X4 the ATV is in 4X4 and the 4X4 indicator icon in the instrument cluster display will be visible When in 4X4 the demand drive unit will automatically engage any time the rear wheels lose traction When the rear wheels regain traction the demand drive unit will automatically disengage There is no limit to the length of time the vehicle may remain in 4X4 The vehicle automatically engages 4X4 when operating in reverse if the switch is set to the 4X4 position 2X4 Mode When the switch is on 2X4 the ATV is in two wheel drive at all times Engaging 4X4 The 4X4 switch may be turned on or off while the vehicle is moving Initially the vehicle s electronic system will not enable 4X4 until the engine RPM is below 3100 Once enabled 4X4 remains enabled until the 4X4 switch is turned off If the switch is turned off while the demand drive unit is moving it will not disengage until the rear wheels regain traction Engage the 4X4 switch before getting into conditions where front wheel drive may be needed If the rear wheels are spinning release the throttle before switching to 4X4 NOTICE Switching to 4X4 while the rear wheels are spinning may cause severe drive shaft and gearcase damage Always switch to 4X4 whi
38. arging Conventional 111 Charging Sealed 111 112 Fluid Conventional 110 Installation 0 109 Removals aerisit iiaea 108 Stora pE kos sek wa ed a onic 110 Belt Lite lt 5 dee caciaeei eee kek 26 BOOts iii s cates vee area ede ae 9 Brake Fluid 85 86 Brake Inspections 87 Brakes FOO sii gee dhe ns eeececee sence 24 Brake Hand 24 Brake Parking soere errosa 25 BEAK CS aeaee aaea sieved 87 Break In Period 38 39 Breather Hose 95 Breather Valve 95 Cc Camber Adjustment 113 CaP 20 ios cece ewes eetases 56 57 Caster Adjustment 113 Check Engine Indicator 35 Chrome Wheel Care 117 Cleaning and Storage 115 120 Clothiig occ iinssindeseaaed sinni 9 Clutching Chart 128 Coolant Bottle 83 Coolant Radiator 84 Cooling System 83 84 Corrosion Removal Chrome 117 D Demand Drive Fluid 82 Diagnostic Codes 36 37 Display Units Standard Metric 32 Drive Belt Wear Burn 122 Drivetrain Break In 39 Driving Downhill 47 Driving in Reverse 54 Driving on a Sidehill 46 Driving on Slippery Surfaces 50 Driving Over Obstacles 51 Driving Procedures 42 Driving Safely
39. ark Gear Signal Error or shifter between gears Fuel Gauge Display The segments of the fuel gauge show the level of fuel in the fuel tank When the last segment clears a low fuel warning is activated All segments including the fuel icon will flash Refuel immediately If the fuel icon fails to display an open or short circuit has occurred in the fuel sensor circuit See your dealer Information Display This area displays odometer trip meter engine hour meter engine speed and programmable service hour interval Clock Display The clock displays time in a 12 hour or 24 hour format If the engine is turned off press the MODE button The time will display for 5 10 seconds See page 33 for resetting instructions Service Reminder Display A flashing wrench symbol alerts the operator that the preset service interval has been reached The vehicle should be brought to your dealer for scheduled maintenance See page 33 for resetting instructions 4X4 Display This icon displays when the 4X4 system is engaged 31 FEATURES AND CONTROLS Instrument Cluster Digital Analog Gauge Rider Information Center The reverse override button acts as the MODE button when pressed and released quickly The transmission cannot be in reverse when using the override button as a MODE button This feature does not contain a vehicle speed lockout function and can be used at any operating speed Display Units Standard Metric The display
40. arying throttle for 10 15 seconds to expel the moisture and air dry the belt and clutches Do not hold the throttle wide open for more than 10 seconds 5 Allow the engine RPM to settle to idle speed then shift the transmission to the lowest available range 6 Test for belt slippage If the belt slips repeat the process 7 Take the vehicle to your dealer for service as soon as possible 106 MAINTENANCE Battery A WARNING Improperly connecting or disconnecting battery cables can result in an explosion and cause serious injury or death When removing the battery always disconnect the negative black cable first When reinstalling the battery always connect the negative black cable last A WARNING Battery electrolyte is poisonous It contains sulfuric acid Serious burns can result from contact with skin eyes or clothing Antidote External Flush with water Internal Drink large quantities of water or milk Follow with milk of magnesia beaten egg or vegetable oil Call physician immediately Eyes Flush with water for 15 minutes and get prompt medical attention Batteries produce explosive gases Keep sparks flame cigarettes etc away Ventilate when charging or using in an enclosed space Always shield eyes when working near batteries KEEP OUT OF REACH OF CHILDREN Your ATV may have either a sealed battery which requires little maintenance or a conventional battery A sealed battery can be identified by it
41. ater 1 2 52 Check water depth and current before crossing Avoid operating in water deeper than the bottom of the footrests If it s unavoidable travel slowly balance your weight carefully and avoid sudden movements Maintain a slow and steady forward motion Do not make sudden turns stops or throttle changes Choose a crossing where both banks have gradual inclines Drive slowly Avoid rocks and obstacles Wet brakes may have reduced stopping ability Always test your brakes after leaving water If necessary apply them lightly several times to allow friction to dry out the pads OPERATION Driving Through Water If your vehicle becomes fully 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 promptly If water has been ingested into the transmission PVT follow the pro cedure on page 102 A Always follow the procedures outlined in this manual for driving through water Never drive through deep or fast flowing water A If the vehicle stops while fully submerged major engine damage can result if the machine is not thoroughly inspected Take the vehicle to your dealer before starting the engine 53 OPERATION Driving in Reverse x e YA se Gi Pa y SH Jeary NS Follow these precautions when operating in reverse Always check for obstacles or people behind the vehicle Always avoid ba
42. bout maintaining a sealed battery is to keep it fully charged Since the battery is sealed and the sealing strip cannot be removed you must use a voltmeter or multimeter to measure DC voltage WARNING An overheated battery may explode causing severe injury or death Always watch charging times carefully Stop charging if the battery becomes very warm to the touch Allow it to cool before resuming charging For a refresh charge follow all instructions carefully 1 Check the battery voltage with a voltmeter or multimeter A fully charged battery will register 12 8 V or higher 2 Ifthe voltage is less than 12 8 volts recharge the battery at 1 2 amps or less until battery voltage is 12 8 or greater 3 When using an automatic charger refer to the charger manufacturer s instructions for recharging When using a constant current charger use the guidelines on the next page for recharging 111 MAINTENANCE Battery Battery Charging Sealed Battery Always verify battery condition before and 1 2 hours after the end of charging State of Charge Time Voltage Action Using constant current Charge charger standard amps specified on top of battery 100 12 8 13 0 volts None check at 3 None required mos from date of manufacture 75 100 12 5 12 8 volts May need slight 3 6 hours charge if no charge given check in 3 months Needs charge 5 11 hours 50 75 12 0 12 5 volts 25 50 11 5 12 0 volts Ne
43. can be changed to display either standard or metric units of measurement Tip To exit the set up mode at any time wait 10 seconds The display automatically exits and returns to the odometer display Standard Display Metric Display Distance Miles Kilometers Time 12 Hour Clock 24 Hour Clock Turn the key to the OFF position 2 Place the transmission in neutral 3 Press and hold the MODE button while turning the key to the ON position 4 When the display flashes the distance setting tap the MODE button to advance to the desired setting 5 Press and hold the MODE button to save the setting and advance to the next display option 6 Repeat the procedure to change remaining display settings 32 FEATURES AND CONTROLS Instrument Cluster Digital Analog Gauge Rider Information Center Clock Mode Tip The clock must be reset any time the battery has been disconnected or discharged 1 Turn the key to the ON position Use the MODE button to toggle to the odometer display 2 Press and hold the MODE button until the hour segment flashes Release the button 3 With the segment flashing tap the MODE button to advance to the desired setting 4 Press and hold the MODE button until the next segment flashes Release the button 5 Repeat steps 3 4 twice to set the 10 minute and 1 minute segments After completing the 1 minute segment step 4 will save the new settings and exit the clock mode 6
44. cking downhill Back slowly Apply the brakes lightly for stopping Avoid turning at sharp angles Never open the throttle suddenly Do not use the override button unless additional wheel speed is required for vehicle movement Use the override with caution as rearward vehicle speed is greatly increased Do not operate at wide open throttle Operate the throttle just enough to maintain a desired speed SY Bop oe NS A Excessive throttle operation while in the speed limit mode may cause fuel to build in the exhaust resulting in engine popping and or engine damage A Always follow the procedures outlined in this manual for driving in reverse 54 OPERATION Parking on an Incline Avoid parking on an incline if possible If it s unavoidable follow these precautions 1 Stop the engine 2 Place the transmission in PARK 3 Always block the rear wheels on the downhill side 55 OPERATION H auling Cargo A Overloading the vehicle or carrying or towing cargo improperly can alter vehicle ha ndling and may cause loss of control or brake instability Always follow these precautions when hauling cargo e 56 Read and understand the load distribution warnings listed on the vehicle warning labels Never exceed the stated load capacity for this vehicle REDUCE SPEED AND ALLOW GREATER DISTANCES FOR BRAKING WHEN HAULING CARGO OR TOWING Use extreme caution when applying brakes Avoid situations that requ
45. cle read the owner s manual e For your nearest Polaris dealer Q PGLARIS fiy eoororaRs or visit www polaris com Polaris Sales Inc 2100 Hwy 55 Medina MN 55340 Phone 1 888 704 5290 Part No 9924299 Rev 01 Printed in USA 9924299
46. d Rear WARNING DO NOT TOW FROM RACK OR BUMPER Vehicle damage or tipover may result causing severe injury or death Tow only from tow hooks or hitch Maximum Rack Loads Front 90 Ibs 41 kg Rear 180 Ibs 82 kg A Reverse Override Alert Pushing reverse override button may cause sudden increases 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 18 SAFETY Safety Labels and Locations 4X4 AWD No Passenger Reverse Override Warning Warning Warning cor Rack Rack L Gieh Pover Warning Warnin Warning A K od a Age 16 Warning Tire Pressure Load Warning Clutch Cover Warning WARNING e Moving parts hazard under belt clutch guard To prevent serious injury do not operate vehicle with guard removed Do not modify engine or clutch Doing so can cause part failure possible imbalance and excessive engine RPM which can result in serious injury or death NO STEP Rack Warning Front and Rear WARNING DO NOT TOW FROM RACK OR BUMPER Vehicle damage or tipover may result causing severe injury or death Tow only from tow hooks or hitch e Max Rack Loads Front 90 Ibs 41 kg Rear 180 Ibs 82 kg Reverse Override Warning WARNING Improper use of override button can lead to loss of control resulting in serious injury or death Do not activate override while throttle is engaged Always apply throttle grad
47. d damaging the tree during winch operation Sharp cables and chains can damage and even kill trees Please remember to TreadLightly treadlightly org Before operating the winch be sure that the safety latch on the winch cable hook is fully seated when the load is attached Never operate your winch with a damaged hook or latch Always replace damaged parts before using the winch YES NO WINCH GUIDE Winch Operation S 6 7 10 Never remove the hook strap from the hook Release the winch clutch and pull out the winch cable Pulling out as much cable as possible maximizes the winch s pulling capacity Always be sure that at least five 5 full turns of winch cable are wrapped around the winch drum at all times The friction provided by this wrapped cable allows the drum to pull on the winch cable and move the load Read and adhere to the following information for winch damping to ensure safe winch use A In order to absorb energy that could be released by a winch cable failure always place a damper on the winch cable A damper can be a heavy jacket tarp or other soft dense object A damper can absorb much of the energy released if a winch cable breaks when winching Even a tree limb can help as a damper if no other items are available to you B Lay the damper on top of the mid point of the winch cable length that is spooled out C On a long pull it may be necessary to stop winching so that the damper
48. damage and must be drained Water accumulation increases as outside temperature decreases 41 OPERATION Driving Procedures N SS Ser amp 42 Wear a helmet and eye protection See page 8 Sit upright with both feet on the footrests and both hands on the handlebars Start the engine and allow it to warm up Shift the transmission into gear Check your surroundings and determine your path of travel Slowly depress the throttle with your right thumb and begin driving Drive slowly Practice maneuvering and using the throttle and brakes on level surfaces OPERATION Turning the Vehicle 1 Before turning activate a turn signal to alert others of your intentions Activate the left signal before a left turn Activate the right signal before a right turn 2 Steer in the direction of the turn leaning your upper body to the inside of the turn while supporting your weight on the outer footrest Use the same leaning technique for turning in reverse 3 Practice making turns at oe cae slow speeds before See attempting to turn at faster f speeds A Always follow the procedures outlined in this manual for turning Never turn sharply at excessive speeds which can lead to vehicle overturn 43 OPERATION Driving Uphill 25 Maximum Braking and handling are greatly affected when operating in hilly terrain Improper procedure could cause loss of control or rollover Whenever traveling up
49. e ATV unless the guest has read this manual and all product labels and has completed a certified safety training course e This vehicle is approved for OFF ROAD TOWING ONLY Towing a trailer with this vehicle on public roads is prohibited INTRODUCTION Vehicle Identification Numbers Record your vehicle s identification numbers and key number in the spaces provided Remove the spare key and store it in a safe place An ignition key can be duplicated only by ordering a POLARIS key blank using your key number and mating it with one of your existing keys The ignition switch must be replaced if all keys are lost front or rear frame Key Number Engine Serial NY Number Vehicle Model Number Frame VIN Engine Serial Number Key Number INTRODUCTION European Vibration and Noise The driver perceived noise and hand arm and whole body vibration levels of this machinery is measured per prEN 15997 The operating conditions of the machinery during testing The vehicles were in like new condition The environment was controlled as indicated by the test procedure s The uncertainty of vibration exposure measurement is dependent on many factors including e Instrument and calibration uncertainty e Variations in the machine such as wear of components e Variation of machine operators such as experience or physique e Ability of the worker to reproduce typical work during measurements e Environmental factors s
50. e lights do not operate unless the main key switch is on and the engine stop switch is in the RUN position ED High Beam D Low Beam Turn Signal Switch QO Push the toggle switch either left or right to activate the corre sponding turn signal light The indicator on the pod will also flash Return the toggle to the center position to end the signal Horn Switch bo Press the horn switch to sound the horn Hazard Warning Switch Push the hazard warning switch to cause all turn signal lights to flash simultaneously Use this feature to alert others of an emergency or other situation requiring caution 21 FEATURES AND CONTROLS Switches Momentary High Beam Switch Winch Switch Main Key Switch Momentary High Beam Switch Press this switch with your left forefinger to activate the headlight high beam The lights will return to low beam when the switch is released Winch Switch See page 58 for winch information Main Key Switch ge End all electrical power to the vehicle D LIGHTS ON position turns the headlights on O Start the engine The headlights are not on in this position dE After starting the engine release the key switch to the PARKING LIGHTS ON position The parking lights and taillights are on in this position See page 41 for starting procedures 4X4 Switch Use the 4X4 switch to engage 4X4 or 2X4 See page 27 Mirrors Use the mirrors to assist in traffic maneuvers Always chec
51. e vehicle unless they have read and understand this manual and all product labels and have completed a certified safety training course A Never allow anyone under 16 years of age to operate this vehicle SQ A Never carry a passenger The purpose of the long seat is to allow the operator to shift position 10 SAFETY Operator Safety A Always wear an approved helmet that fits properly Wear eye protection goggles or face shield gloves boots long sleeves and long pants A Never consume alcohol or drugs before or while operating this vehicle A Never operate at excessive speeds Travel and turn at speeds appropriate for the terrain visibility operating conditions and your experience A Never attempt jumps or other stunts 11 SAFETY Operator Safety A Always inspect your POLARIS vehicle before each use to verify that it s in safe operating condition Follow the inspection and maintenance procedures outlined in this manual See page 40 A Keep both hands on the handlebars Keep your feet on the footrests A Always travel slowly when operating on unfamiliar terrain Use extra caution A Always follow the procedures outlined in this manual for turning See page 43 Never turn sharply at excessive speeds which can lead to vehicle overturn 12 SAFETY Operator Safety A If the vehicle has been involved in an accident always have an authorized POLARIS dealer in
52. eated by fogging and damage could occur Never start the engine during the storage period Clean the Exterior Make any necessary repairs and clean the vehicle as recommended See page 115 Stabilize the Fuel 1 Fill the fuel tank 2 Add POLARIS Carbon Clean Fuel Treatment or POLARIS Fuel Stabilizer Follow the instructions on the container for the recommended amount Carbon Clean removes water from fuel systems stabilizes fuel and removes carbon deposits from pistons rings valves and exhaust systems 3 Allow the engine to run for 15 20 minutes to allow the stabilizer to disperse through the entire fuel delivery system Oil and Filter Change the oil and filter See page 78 Air Filter Air Box 1 Inspect and clean or replace the pre cleaner and air filter See page 94 2 Clean the air box Drain the sediment tube a 4 Clean or replace the breather valve See page 95 118 MAINTENANCE Cleaning and Storage Storage Tips Fluid Levels Inspect the fluid levels Add or change fluids as recommended in the Periodic Maintenance Chart beginning on page 71 e Demand drive unit front gearcase e Rear gearcase if equipped e Transmission e Brake fluid change every two years and any time the fluid looks dark or contaminated e Coolant test strength fill Fog the Engine 1 After stabilizing the fuel remove the spark plugs and add 2 3 tablespoons of engine oil To access the plug holes use a section of clea
53. eds charge At least 13 hours verify state of charge 0 25 11 5 volts or less Needs charge with desulfating charger At least 20 hours 112 MAINTENANCE Camber and Caster The camber and caster are non adjustable Rear Spring The rear shock absorber spring is adjusted by rotating the cam either clockwise or counter clockwise to increase or decrease spring tension Accessory springs are available through Cam your POLARIS dealer Handlebars The handlebars can be adjusted for rider Ty preference WARNING Improper adjustment of the High handlebars or incorrect torquing of the adjuster Tension block tightening bolts can cause limited steering Low or loosening of the handlebars resulting in loss Tension of control and serious injury or death Follow the adjustment procedures exactly or see your POLARIS dealer for service 1 Remove the upper headlight pod 2 Loosen the four handlebar bolts 3 Adjust the handlebar to the desired height 4 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 5 Torque the front two bolts to 10 12 ft Ibs 14 17 Nm then Handlebar torque the rear two bolts A Bolts gap of up to 1 8 3 mm will remain at the rear of the clamp blocks 113 MAINTENANCE Throttle Body Idle RPM Idle RPM is preset by the manufacturer If the engine idle speed is not satisfactory
54. egistered to Government officials or military personnel on assignment outside of the country where the product was purchased will continue to be covered by the Limited Warranty Please work with your dealer to resolve any warranty issues Should your dealer require any additional assistance they will contact the appropriate person at POLARIS This warranty gives you specific legal rights and you may also have other rights which vary from state to state or in different countries If any of the above terms are void because of federal state local law all other warranty terms will remain in effect For questions call POLARIS Customer Assistance United States amp Canada 1 800 POLARIS 1 800 765 2747 French 1 800 268 6334 132 MAINTENANCE LOG Present this section of your manual to your dealer each time your vehicle is serviced This will provide you and future owners with an accurate log of maintenance and services performed DATE MILES KM OR HOURS TECHNICIAN SERVICE PERFORMED COMMENTS 133 MAINTENANCE LOG DATE MILES KM OR HOURS TECHNICIAN SERVICE PERFORMED COMMENTS 134 0 9 4X4 Switch 00 22 27 A ACCESSOTIESs fact nth aati dao akaes 120 Air Filter 0 0 0 0 00 eee ee 94 All Wheel Drive System 27 B Battery 0 cece eee 107 112 Ch
55. er Using an oil filter wrench available from your POLARIS dealer turn the filter counter clockwise to remove it Using a clean dry cloth clean the filter sealing surface on the crankcase MAINTENANCE Engine Oil Oil and Filter Change 11 12 13 14 15 16 17 18 19 20 Lubricate the o ring on the new filter with a film of fresh engine oil Check to make sure the o ring is in good condition Install the new filter and rotate it clockwise by hand until the filter gasket contacts the sealing surface then turn it an additional 1 2 turn Remove the dipstick Add two quarts 1 9 1 of recommended oil Place the transmission in PARK Start the engine Allow it to idle for one to two minutes Stop the engine Check for leaks Check the oil level Add oil as needed to bring the level to the upper mark on the dipstick Dispose of used filter and oil properly 79 MAINTENANCE Transmission Oil Always check and change the transmission oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 71 Maintain the oil level at the bottom of the fill plug hole threads See page 126 for the part numbers of POLARIS products The fill plug is located on the left side of the ATV under the rear fender behind the wheel The drain plug is located on the right side of the gearcase on the right side of the ATV behind the wheel well Check Fill Plug Drain Plug Transmis
56. event inadvertent activation and use by unauthorized persons Never grease or oil the winch cable This will cause the winch cable to collect debris that will shorten the life of the cable WINCH GUIDE Winch Operation Read the Winch Safety Precautions in the preceding pages before using your winch Tip Consider practicing the operation and use of your winch before you actually need to use it in the field A WARNING Improper winch use can result in SEVERE INJURY or DEATH Always follow all winch instructions and warnings in this manual Each winching situation is unique Take your time to think through the winching you are about to do e Proceed slowly and deliberately e Never hurry or rush during winching e Always pay attention to your surroundings e You may need to change your winching strategy if it is not working Always remember that your winch is very powerful e There are simply some situations that you and your winch will not be able to deal with Do not be afraid to ask others to help when this happens 1 Always inspect the vehicle winch winch cable and winch controls for any signs of damage or parts in need of repair or replacement before each use Pay particular attention to the first 3 feet 1 meter of winch cable if the winch is being used or has been used for lift ing an accessory plow assembly Promptly replace any worn or damaged cable 2 Never operate a winch or a vehicle in need of repair or se
57. factory for optimal performance and are not adjustable Electromagnetic Interference This spark ignition system complies with Canadian ICES 002 This vehicle complies with the EMC requirements of European directives 97 24 EC and 2004 108 EC Non ionizing Radiation This vehicle emits some electromagnetic energy People with active or non active implantable medical devices such as heart monitoring or controlling devices should review the limitations of their device and the applicable electromagnetic standards and directives that apply to this vehicle 70 MAINTENANCE Periodic Maintenance Chart Careful periodic maintenance will help keep your vehicle in safe reli able condition Inspect clean lubricate adjust and replace parts as nec essary When inspection reveals the need for replacement parts use genuine POLARIS parts available from your POLARIS dealer Record maintenance and service in the Maintenance Log beginning on page 133 Service and adjustments are important for proper vehicle operation If you re not familiar with safe service and adjustment procedures have a qualified dealer perform these operations Maintenance intervals in the following chart are based upon average riding conditions and an average vehicle speed of approximately 10 miles per hour Vehicles subjected to severe use must be inspected and serviced more frequently Severe Use Definition e Frequent immersion in mud water or sand e Racing or race
58. fill lines See page 85 Transmission Oil AGL Gearcase 32 oz 948 ml Maintain level at bottom of fill Lubricant amp hole threads See page 80 Transmission Fluid Demand Drive Demand Drive 9 oz 265 ml Maintain level at bottom of fill Fluid Fluid hole threads See page 82 Front Gearcase Front Prop Shaft U Joint Grease Grease fittings 3 pumps Yoke maximum every 500 miles before long periods of storage or after pressure washing or submerging Front Prop Shaft Yoke 75 MAINTENANCE Engine Oil Oil Recommendations Lubricant Capacity Drain Plug Torque PS 4 5W 50 4 Cycle Oil 2 ats 1 9 I 14 17 ft lbs 19 23 Nm Always change the oil filter whenever changing oil POLARIS recommends the use of POLARIS PS 4 Full Synthetic 5W 50 4 cycle oil or a similar oil for this engine Oil may need to be changed more frequently if POLARIS oil is not used Always use 5W 50 oil Follow the manufacturer s recommendations for ambient temperature operation See page 126 for the part numbers of POLARIS products NOTICE Mixing brands or using a non recommended oil may cause serious engine damage Always use the recommended oil Never substitute or mix oil brands 76 MAINTENANCE Engine Oil Oil Level Access the oil dipstick and fill tube from the right side of the ATV A rising oil level between checks in cool weather driving can indicate contaminants such as gas or
59. gnal Fault 523 2 Injector 1 MAG Driver Circuit Open Grounded 651 5 Driver Circuit Short to B 651 3 Ignition Coil Primary Driver 1 MAG Driver Open Grounded 1268 5 Driver Circuit Short to B 1268 3 Fuel Pump Driver Circuit Driver Circuit Open Grounded 1347 5 Driver Circuit Short to B 1347 3 Fan Relay Driver Circuit Driver Circuit Open Grounded 1071 5 Driver Circuit Short to B 1071 3 36 FEATURES AND CONTROLS Instrument Cluster Diagnostic Display Code Definitions SPORTSMAN 570 EFI 570 EPS Diagnostic Codes Component Condition SPN FMI Idle Air Control Driver Circuit Grounded 520193 5 Shorted Load 520193 11 Starter Enable Circuit Driver Circuit Short to B 1321 3 All Wheel Drive Control Driver Circuit Short to B 520207 3 System Power Voltage Too High 168 3 Voltage Too low 168 4 Throttle Safety Signal Voltage Too High 520194 3 Voltage Too Low 520194 4 Signal Out of Range 520194 2 Throttle Stuck 520194 7 Active Descent Control System Driver Circuit Short to B 520203 3 EPS Models Only Steering Over Current Shut Down Current Above Normal or 520221 6 Grounded Steering Excessive Current Error Current Above Normal or 520222 6 Grounded Steering Torque Sensor T1 Partial T1 Shorted to Ground 520223 4 Failure T1 Shorted to Bus 520223 3 Steering Torque Sensor T2 Partial T2 Shorted to Ground 520224 4 Failu
60. h Momentary 22 High Range Uses c0 6 csicenaens 106 Horn Switch sslcchs wee eens 21 l Idle RPM Adjustment 114 Immersion Maintenance 102 Indicator Lamps 29 Instrument Cluster 28 37 K Key SWiteh sensensa sinistia 22 KETT coseno meere pai 48 49 L Light Switi egan a 22 Tights sosisor5 550 sressesnavetsnsveyereeyerars 97 99 Front Turn Signal 99 Headlight Lamp 98 High Beam Adjustment 97 Low Beam Adjustment 97 Parking Light Lamp 98 Position Light Lamp 98 Rear Turn Signal 99 Dam MGs ea naati reak 99 136 L Low Beam Adjustment 97 Low Range Use 106 Lubrication Guide T5 M Maintenance Chart 71 74 Metric Display 0 32 MITOS 6 ose Ssceas wena diane bane ec 22 Mode Switch 2 0005 20 Modifications 0005 9 N Noise Emission Control System 70 O Oil Engine sited beeen eiki 76 79 Transmission 80 81 Oil and Filter Change 78 79 Oil Change Transmission 81 Oil Level ENGINE f o sctvia ch ceva aun op Meopite ctaiteun 77 Transmission 00 81 Oil Recommendations 76 Operator Safety 10 16 Override Switch 20 P Parking Brake 25 Parking on an Incline 55 Periodic Maintenance Chart 71 74 Polari
61. hill follow these precautions 1 Drive straight uphill Avoid steep hills 25 maximum Always check the terrain carefully before ascending any hill Never climb hills with excessively slippery or loose surfaces Keep both feet on the footrests Shift your weight uphill a OY eS Proceed at a steady rate of speed and throttle opening Opening the throttle suddenly could cause the ATV to flip over backwards 8 Remain alert and be prepared to take emergency action This may include quick dismounting of the vehicle 44 OPERATION Driving Safely Driving Uphill If all forward speed is lost Keep your weight uphill If the vehicle begins rolling downhill never apply engine power Never apply the brakes aggressively while rolling backwards Apply the brakes gradually When fully stopped lock the hydraulic parking brake See page 25 Dismount on the uphill side or to either side if the vehicle is pointed straight uphill Turn the vehicle around using the K Turn See page 48 A Always follow the procedures outlined in this manual for climbing hills Avoid climbing hills steeper than 25 A Always follow the procedures outlined in this manual for braking if you stall or roll backwards while climbing a hill Never back down a hill 45 OPERATION Driving on a Sidehill Sidehilling Driving on a sidehill is not recommended Improper procedure could cause loss of control or rollover Avoid crossing the side
62. ill 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 e Always follow all recommended maintenance procedures Always look for and remove debris inside and around the clutch and vent system when replacing the belt e See your dealer as outlined in the owner s manual e This PVT system is intended for use on POLARIS products only Do not install it in any other product Always make sure the PVT housing is securely in place during operation 104 MAINTENANCE PVT System The basic operation of the POLARIS PVT system is dependent on engine speed and vehicle torque requirements As engine speed increases the force exerted on the movable drive sheave by the flyweights also increases This in turn increases the amount of pinch applied to the drive belt Similarly if the engine speed decreases the amount of centrifugal force decreases reducing the amount of belt pinch On POLARIS ATVs the approximate gear ratio difference between high and low range is 1 2 25 This difference in gearing affects the operation of the PVT especially at speeds less than 7 MPH 11 km h due to the system s dependence on engine speed
63. ill result in more efficient performance and longer life for these components NOTICE Excessive heat build up during the first three hours of operation will damage close fitted engine parts and drive components Do not operate at full throttle or high speeds during the first three hours of use 38 OPERATION Break In Period Engine and Drivetrain Break in 1 Fill the fuel tank with gasoline See page 26 Always exercise extreme caution whenever handling gasoline 2 Check the oil level on the dipstick See page 77 Add oil if necessary to maintain the level between the safe and add marks 3 Drive slowly at first Select an open area that allows room to familiarize yourself with vehicle operation and handling 4 Vary the throttle positions Do not operate at sustained idle 5 Perform regular checks on fluid levels controls and areas outlined on the daily pre ride inspection checklist See page 40 6 Pull only light loads Change both the oil and the filter at 25 hours Check fluid levels of transmission and all gearcases after the first 25 hours of operation and every 100 hours thereafter PVT Break in Clutches Belt A proper break in of the clutches and drive belt will ensure a longer life and better performance Break in the clutches and belt by operating at slower speeds during the break in period as recommended Pull only light loads Avoid aggressive acceleration and high speed operation during the break in period
64. ins on after starting the engine the EPS system is inoperative See your authorized POLARIS dealer for service N Neutral This lamp illuminates when the transmission is in neutral and the ignition key is in the ON position High Beam This lamp illuminates when the headlamp switch is 0000 set to high beam Check Engine This indicator appears if an EFl related fault occurs Do not operate the ATV if this warning appears Serious engine damage could result See your dealer 29 FEATURES AND CONTROLS Instrument Cluster Digital Analog Gauge Rider Information Center The rider information center is located in the instrument cluster All segments will light up for one second at start up If the instrument cluster fails to illuminate a battery over voltage may have occurred and the instrument cluster may have shut off to protect the electronic speedometer If this occurs take the ATV to your POLARIS dealer for proper diagnosis The information center is set to display standard units of measurement and a 12 hour clock at the factory To change to metric and or a 24 hour clock see page 33 2 2 ae a a O F f TA TIA IHA VA 1 BZA VW NA A A 3 IAN AN TANTAN UNUAN IZN 30 FEATURES AND CONTROLS Instrument Cluster Digital Analog Gauge Rider Information Center 1 Tip Gear Display This area displays gear shifter position H High Gear L Low Gear N Neutral R Reverse Gear P P
65. ip and provides no coverage for consumable components general wear items or any parts exposed to friction surfaces stresses environmental conditions and or contamination for which they were not designed or not intended including but not limited to the following items Finished and unfinished surfaces Carburetor Throttle body components Engine components Drive belts Hydraulic components and fluids Circuit breakers Fuses Wheels and tires Suspension components Brake components Seat components Clutches and components Steering components ee o o o oo o ee o o o o o o Batteries Electronic components Light bulbs Sealed beam lamps Spark plugs Filter Sealants Lubricants Coolants Bushings Bearings Lubricants and Fluids 1 Mixing oil brands or using non recommended oil may cause engine damage We recommend the use of POLARIS engine oil 2 Damage or failure resulting from the use of non recommended lubricants or fluids is not covered by this warranty This warranty provides no coverage for personal loss or expense including mileage transportation costs hotels meals shipping or handling fees product pick up or delivery replacement rentals loss of product use loss of profits or loss of vacation or personal time THE EXCLUSIVE REMEDY FOR BREACH OF THIS WARRANTY SHALL BE AT POLARIS OPTION REPAIR OR REPLACEMENT OF ANY DEFECTIVE MATERIALS COMPONENTS OR PRODUCTS THE REMEDIES SET FORTH IN THIS WAR
66. ire backing downhill When operating over rough or hilly terrain reduce speed cargo and towed load to maintain stable driving conditions CARRY LOADS AS LOW ON THE RACK AS POSSIBLE Carrying a load high on the rack raises the center of gravity of the vehicle and creates a less stable operating condition Reduce load weight when cargo is high Secure off centered loads that cannot be centered and operate with extra caution CARRYING A LOAD on only one rack may cause the vehicle to overturn Split the load between the front rack and rear rack with 1 3 in the front and 2 3 in the back Do not exceed load capacities See specifications beginning on page 127 SECURE ALL LOADS BEFORE OPERATING Unsecured loads can create unstable operating conditions which could result in loss of control of the vehi cle OPERATE ONLY WITH STABLE AND SAFELY ARRANGED LOADS When handling off centered loads that cannot be centered securely fasten the load and operate with extra caution Always attach the tow load to the hitch point designated for your vehicle USE EXTREME CAUTION when operating with loads that extend over the rack sides Stability and maneuverability may be adversely affected causing the vehicle to overturn NEVER exceed 80 km h when rear cargo loads are above 34 kg and or front cargo loads are above 17 kg TOWING is approved OFF ROAD ONLY Operating this vehicle with a trailer on public roads is prohibited TOWING SPEED should never exceed
67. k and adjust the mirrors before driving the vehicle 22 FEATURES AND CONTROLS Throttle Lever A Failure to check or maintain proper operation of the throttle system can result in an accident if the throttle lever sticks during operation Check the lever for proper operation before starting the engine Check occasionally during operation Do not start or operate a vehicle with sticking or improperly operating throttle controls Contact your dealer for repair if throttle problems arise Press the throttle lever to increase engine speed and vehicle movement Release the lever to reduce engine speed and vehicle movement This vehicle is equipped with a throttle release switch which is designed to reduce the risk of a frozen or stuck throttle If the throttle cable should stick in an open position when the operator releases the throttle lever the engine will stop and power to the rear wheels will cease Electronic Power Steering EPS Electronic power steering EPS if equipped engages when the ignition key is turned to the ON position EPS remains engaged whether the vehicle is moving or idle See page 29 for EPS Warning Indicator infor mation 23 FEATURES AND CONTROLS Foot Brake The all wheel foot brake is located Foot Brake on the right footrest The foot brake operates both front and rear brakes Press the brake pedal down with your foot to apply the all wheel brakes If the rear wheels begin to skid or
68. l never back it down the hill Use the K turn to turn around Stop the vehicle Keep your weight uphill Lock the hydraulic parking brake Leave the transmission in forward gear Turn the engine off foe Oa Dismount on the uphill side of the vehicle or on the left if the vehi cle is pointing straight uphill Stay uphill of the vehicle and turn the handlebars full left Squeeze the brake lever to release the parking brake Ov 7 Slowly release the brake lever and allow the vehicle to roll around to your right until it s pointing across the hill or slightly downward 48 OPERATION Turning Around on a Hill K Turn 8 Lock the hydraulic parking brake 9 Remount from the uphill side Keep your weight uphill 10 Apply the foot brake 11 With the transmission still in forward start the engine 12 Squeeze and release the brake lever to release the parking brake 13 Release the foot brake and drive slowly downhill Control speed with either the hand or foot brake until the vehicle is on level ground A Always follow the procedures outlined in this manual for climbing hills See page 44 A Always follow the procedures outlined in this manual for braking if you stall or roll backwards while climbing a hill Never back down a hill 49 OPERATION Driving on Slippery Surfaces Whenever riding on slippery surfaces such as wet trails or loose gravel or during freezing weather follow these precaution
69. le the rear wheels have traction or are at rest 27 FEATURES AND CONTROLS Instrument Cluster NOTICE High water pressure may damage ATV components Wash the ATV by hand or with a garden hose using mild soap Certain products including insect repellents and chemicals will damage the speedometer lens and other plastic surfaces Do not use alcohol to clean the instrument cluster Do not allow insect sprays to contact the lens Immediately clean off any gasoline that splashes on the instrument cluster Digital Analog Gauge Speedometer The speedometer displays vehicle speed in either miles per hour MPH or kilometers per hour km h Speedometer Indicator Lamps 2 Z A 2 seeeee 2rg58 68 Rider Information Center 28 FEATURES AND CONTROLS Instrument Cluster Digital Analog Gauge Indicator Lamps Lamp Indicates Condition When standard mode is selected speed displays in Vehicle miles per hour Speed gt When metric mode is selected speed displays in kilometers per hour Over This lamp flashes to indicate an overheated engine If REJ Temperature the indicator stops flashing but remains illuminated E the overheating condition remains and the system will automatically reduce engine power EPS Warning This indicator illuminates when the key is turned to if equipped the ON position and goes off when the engine is started If the light rema
70. le while purging Never go under the vehicle while it s inclined The exhaust system can get extremely hot Do not perform service on the spark arrester while the system is hot Allow components to cool sufficiently before proceeding Use the following procedure to periodically purge accumulated carbon from the exhaust pipe muffler 1 Remove the arrester clean out plug from the bottom of the muffler 2 Place the transmission in Exhaust PARK Outlet lt 4 3 Start the engine a re 4 Quickly squeeze and release Clean Out Plug the throttle lever several times to purge carbon from the system 5 If carbon comes out of the exhaust cover or plug the exhaust outlet Wear protective gloves 6 Lightly tap on the exhaust pipe with a rubber mallet while repeating step 4 7 If particles are still suspected to be in the muffler elevate the rear of the vehicle one foot 30 cm higher than the front Block the wheels 8 Repeat steps 4 to 6 until no more particles are expelled Stop the engine Allow the arrester to cool 10 Reinstall the arrester plug and remove the exhaust outlet cover or plug 103 MAINTENANCE PVT System A WARNING Failure to comply with the instructions in this warning can result in severe injury or death Do not modify any component of the PVT system Doing so may reduce its strength so that a failure may occur at a high speed The PVT system has been precision balanced Any modification w
71. lt in serious injury or death Maintain brake fluid at the recommended level Do not overfill Under normal operation the diaphragm extends into the reservoir as fluid level drops If the fluid level is low and the diaphragm is not extended a leak is likely and the diaphragm should be replaced To ensure proper diaphragm operation always fill the reservoir as needed whenever the cover is loosened or removed Do not overfill A 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 85 MAINTENANCE Brake Fluid Hand Brake The master cylinder is located on the left handlebar Maintain the fluid level 6 mm below the top edge of the master cylinder Do not over fill 1 Position the vehicle on a level surface Make sure the handle bars are straight 2 View the fluid level through the indicator window eye on the top of the master cylinder Master Indicator Cylinder Window Tip The eye will appear dark when the fluid level is full When fluid is low the eye will be clear 3 Add the recommended fluid as needed Do not overfill Foot Brake 1 Position the vehicle on a level surface 2 Remove the seat 3
72. ly winch the cable in while your assistant moves the end of the winch cable back and forth horizontally to evenly distribute the winch cable on the drum F Doing this reduces the chances of the winch cable wedging itself between lower layers of winch cable m Jop 65 WINCH GUIDE Winch Cable Care For your safety always replace POLARIS winch parts including the cable with genuine POLARIS replacement parts available at your authorized POLARIS dealer WARNING Use of worn or damaged cable could lead to sudden failure and SEVERE INJURY 1 66 Always inspect your winch before each use Inspect for worn or loose parts including mounting hardware Never use the winch if any part needs repair or replacement Always inspect your winch cable before each use Inspect for worn or kinked winch cable A A kinked winch cable made of wire rope is shown at right Even after being straightened out this cable has already been permanently and severely damaged Promptly discontinue use of a winch cable in this condition A kinked winch cable made of wire rope that has been AEE PCO RSC O TTET straightened out is shown at B right Even though it may look usable the cable has been permanently and severely damaged It can no longer transmit the load that it could prior to kinking Promptly discontinue use of a winch cable in this condition A winch cable made of synthetic rope should be inspected for
73. 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 Remove the dipstick Wipe it dry with a clean cloth 3 Reinstall the dipstick completely 4 Remove the dipstick and check the oil level Maintain the oil sae level in the safe range Do not Pipstiok sale Adwa overfill 77 MAINTENANCE Engine Oil Oil and Filter Change Always change the oil and filter at the intervals outlined in the Periodic Maintenance Chart beginning on page 71 Always change the oil filter whenever changing oil 1 F 6 Position the vehicle on a level surface Start the engine Allow it to warm up at idle for two to three minutes Stop the engine Clean the area around the drain plug Place a drain pan under the crank case Remove the drain plug Allow the oil to drain completely CAUTION Hot oil can cause burns to skin Do not allow hot oil to contact skin he 10 78 Install a new sealing washer on the drain plug The sealing Oil I Filter we r Drain Plug Front View of the Engine surfaces on drain plug and crankcase should be clean and free of burrs nicks or scratches Reinstall the drain plug Torque to 14 18 ft Ibs 19 24 Nm Place shop towels beneath the oil filt
74. n Fill Plug the right side of the demand Al drive unit The drain plug is located on the bottom right side of the unit Fluid Check 1 Position the vehicle on a level surface Remove the fill plug Check the fluid level Fill Level Drain Plug 2 Add the recommended demand drive fluid as needed to bring the level to the bottom of the fill hole threads 3 Reinstall the fill plug Torque to 8 10 ft Ibs 11 14 Nm Fluid Change 1 Position the vehicle on a level surface Remove the fill plug Place a drain pan under the demand drive unit 2 Remove the drain plug Allow the fluid to drain completely 3 Clean and reinstall the drain plug Torque to 11 ft lbs 15 Nm 4 Add the recommended fluid See page 82 for capacity Maintain the fluid level at the bottom of the fill hole threads 5 Reinstall the fill plug Torque to 8 10 ft Ibs 11 14 Nm 6 Check for leaks Dispose of used fluid properly 82 MAINTENANCE Cooling System The engine coolant level is controlled or maintained by the recovery system The recovery system components are the recovery bottle the radiator filler neck the radiator pressure cap and the connecting hose As coolant operating temperature increases the expanding heated excess coolant is forced out of the engine past the pressure cap and into the recovery bottle As engine coolant temperature decreases the contracting cooled coolant is drawn back up from the b
75. n this manual for driving in reverse See page 54 A Always use the size and type of tires specified for your vehicle Maintain the proper tire pressure A Never modify this POLARIS vehicle through improper installation or use of accessories A Never exceed the stated load capacity for your vehicle Cargo must be properly distributed and securely attached Reduce speed and follow the instructions in this manual for carrying cargo or towing NEVER exceed 80 km h when rear cargo loads are above 34 kg and or front cargo loads are above 17 kg Allowa greater distance for braking 15 SAFETY Operator Safety A Never operate the vehicle on a frozen body of water unless you have independently verified that the ice is sufficiently thick to support the weight and moving force of the vehicle you and your cargo together with any other vehicles in your party A Operating on paved surfaces may affect the handling and control of the vehicle and could result in loss of control Avoid sudden turns or swift movement of the handlebars A Always remove the ignition key when the vehicle is not in use to prevent unauthorized use or accidental starting A Always unlock the steering before starting the engine See page 25 A Hot components can cause serious burns and fire Do not touch hot exhaust system components Always keep combustible materials away from the exhaust system For more information about safety contact an
76. nder 16 years of age to operate the winch PES Always wear eye protection and heavy gloves when operating the winch 5 Always keep body hair clothing and jewelry clear of the winch cable fairlead and hook when operating winch 6 Never attempt to jerk a load attached to the winch with a moving vehicle See the Shock Loading section on page 67 7 Always keep the area around the vehicle winch winch cable and load clear of people especially children and distractions while operating the winch 8 Always turn the vehicle ignition power OFF when it and the winch are not being used 9 Always be sure that at least five 5 full turns of winch cable are wrapped around the winch drum at all times The friction provided by this wrapped cable allows the drum to pull on the winch cable and move the load 10 Always apply your vehicle s park brake and or park mechanism to hold the vehicle in place during winching Use wheel chocks if needed 58 WINCH GUIDE Winch Safety Precautions 11 12 13 14 15 16 17 18 19 Always align the vehicle and winch with the load directly in front of the vehicle as much as possible Avoid winching with the winch cable at an angle to the winching vehicle s centerline whenever possible If winching at an angle is unavoidable follow these precautions A Look at the winch drum occasionally Never let the winch cable stack or accumulate at one end of
77. ndicates a potential personal injury hazard DANGER A DANGER indicates a hazardous situation that if not avoided will result in death or serious injury WARNING A WARNING indicates a hazardous situation that if not avoided could result in death or serious injury CAUTION A CAUTION indicates a hazardous situation that if not avoided could result in minor or moderate injury NOTICE A NOTICE indicates a situation that could result in property damage The Prohibition Safety Sign indicates an action NOT to take in order to avoid a hazard The Mandatory Action Sign indicates an action that NEEDS to be taken to avoid a hazard INTRODUCTION Failure to heed the warnings and safety precautions contained in this manual can result in severe injury or death A POLARIS ATV is not a toy and can be hazardous to operate This vehicle handles differently than other vehicles such as motorcycles and cars A collision or rollover can occur quickly even during routine maneuvers like turning or driving on hills or over obstacles if you fail to take proper precautions e Read this owner s manual Understand all safety warnings precautions and operating procedures before operating a POLARIS ATV Keep this manual with the ATV Never operate an ATV without proper instruction Take a training course e This vehicle is an ADULT VEHICLE ONLY Operation is prohibited for anyone under 16 years of age e Never permit a guest to operate th
78. ne Runs Irregularly Stalls or Misfires Possible Cause Fouled or defective spark plugs Solution Inspect clean and or replace spark plugs Worn or defective spark plug wires See your dealer Incorrect spark plug gap or heat range Set gap to specs or replace plugs Loose ignition connections Check all connections and tighten Water present in fuel Replace with new fuel Low battery voltage Recharge battery to 12 8 VDC Kinked or plugged fuel tank vent line Inspect and replace Incorrect fuel Replace with recommended fuel Clogged air filter Inspect and clean or replace Reverse speed limiter malfunction See your dealer Electronic throttle control malfunction See your dealer Other mechanical failure Possible Lean Fuel Cause Low or contaminated fuel See your dealer Solution Add or change fuel clean the fuel system Kinked or plugged fuel tank vent line Inspect and replace Low octane fuel Replace with recommended fuel Clogged fuel filter Replace filter Incorrect fuel Possible Rich Fuel Cause Fuel is very high octane Replace with recommended fuel Solution Replace with lower octane fuel Stopping starting without adequate warm up Allow engine to warm up before operating and or stopping Incorrect fuel Replace with recommended fuel Clogged air filter Inspect and clean or replace 124
79. ns All service must be performed by your authorized POLARIS dealer Wheel Removal 1 Stop the engine 2 Place the transmission in PARK 3 Loosen the wheel nuts slightly WARNING Do not service axle nuts that have a cotter pin installed See your POLARIS dealer 4 Elevate the side of the vehicle by placing a suitable stand under the footrest frame 5 Remove the wheel nuts 6 Remove the wheel 92 MAINTENANCE Tires Wheel Installation 1 2 3 4 5 Place the transmission in PARK Place the wheel on the hub with the valve stem toward the outside and rotation arrows on the tire pointing toward forward rotation Install the wheel nuts and finger tighten them Lower the vehicle to the ground Torque the wheel nuts to specification WARNING Loose nuts could cause a tire to come off during operation which could result in an accident or rollover Always ensure that all nuts are torqued to specification Wheel Nut Torque Specifications Check the wheel nut torques occasionally and when they ve been loosened for maintenance service Nut Type Nut Torque Lug Nut Aluminum gt 30 ft Ibs 41 Nm Wheels si PLUS 1 4 TURN SL 2 Piece Flange Nut DA 27 ft Ibs 37 Nm Steel Wheels O 93 MAINTENANCE Air Filter 1 Remove the seat 2 Release the air box cover clips and remove the air box cover 3 Loosen the clamp and remove the filter pike ruler 4 Remove the fabric ty
80. o make up for normal self discharge Battery Tender can be left connected during the storage period and will automatically charge the battery if the voltage drops below a pre determined point See page 126 for the part numbers of POLARIS products Battery Fluid Conventional Battery A poorly maintained battery will Lower Upper deteriorate rapidly Check the battery Mark Mark fluid level often Maintain the fluid level between the upper and lower level marks Add only distilled water Tap water contains minerals that are harmful to a battery 110 MAINTENANCE Battery Battery Charging Conventional Battery 1 Remove the battery from the vehicle to prevent damage from leaking or spilled electrolyte during charging See page 108 2 Charge the battery with a charging output no larger than 1 10 of the battery s amp hr rating Charge as needed to raise the specific gravity to 1 270 or greater 3 Reinstall the battery See page 109 Make sure the positive terminal is toward the front of the vehicle Battery Charging Sealed Battery The following battery charging instructions apply only to the installation of a sealed battery Read all instructions before proceeding with the installation of this battery The sealed battery is already filled with electrolyte and has been sealed and fully charged at the factory Never pry the sealing strip off or add any other fluid to this battery The single most important thing a
81. of any hill unless absolutely necessary If crossing a sidehill is unavoidable follow these precautions Slow down Avoid crossing the side of a steep hill Shift body weight uphill Keep your feet on the footrests Steer slightly into the hill to maintain vehicle direction If the vehicle begins to tip quickly turn the front wheel downhill if possible or dismount on the uphill side immediately A Always follow the procedures outlined in this manual for crossing the side of a hill Never attempt to turn the vehicle around on any hill until you ve mastered on level ground the turning technique outlined in this manual DE oe NS 46 OPERATION Driving Downhill When driving downhill follow these precautions 1 Check the terrain carefully 2 Avoid hills with excessively slippery or loose surfaces 3 Never drive downhill at high speed 4 Slow down 5 Avoid driving downhill at an angle which can cause the vehicle to pitch sharply to one side Drive straight downhill 6 Shift your weight rearward 7 Apply the brakes slightly to aid in slowing A Always follow the procedures outlined in this manual for driving downhill and for braking on hills A Never operate at excessive speeds Travel and turn at speeds appropriate for the terrain visibility operating conditions and your experience 47 OPERATION Turning Around on a Hill K Turn If the vehicle stalls while climbing a hil
82. on layer over the entire nose Generally the electrodes are not worn General causes of fouling are excessive oil use of non recommended oil or incorrect throttle body adjustments 101 MAINTENANCE Vehicle Immersion If your vehicle becomes immersed major engine damage can result if the machine is not thoroughly inspected Take the vehicle to your dealer before starting the engine If it s impossible to take your ATV to a dealer before starting it follow the steps outlined below 1 Move the ATV to dry land or at the very least to water below the footrests 2 Check the air box If water is present dry the air box and replace the filter with a new filter Remove the spark plug 3 4 Turn the engine over several times using the electric start 5 Dry the spark plug Reinstall the plug or install a new plug 6 Attempt to start the engine If necessary repeat the drying procedure 7 Take the ATV to your dealer for service as soon as possible whether you succeed in starting it or not 8 If water has been ingested into the PVT follow the procedure on page 106 for drying out the PVT 102 MAINTENANCE Spark Arrester A WARNING Failure to heed the following warnings while servicing the spark arrester could result in serious injury or death Never run the engine in an enclosed area Remove any combustible materials from the area Wear eye protection and leather work gloves Do not stand behind or in front of the vehic
83. ottle past the pressure cap and into the radiator Some coolant level drop on new vehicles is normal as the system is purging itself of trapped air Check the coolant level and maintain as recommended by adding coolant to the recovery bottle POLARIS recommends the use of POLARIS Antifreeze 60 40 premix or a 50 50 mixture of high quality aluminum compatible anti freeze coolant and distilled water POLARIS Antifreeze is already premixed and ready to use Do not dilute with water See page 126 for the part numbers of POLARIS products Always follow the manufacturer s mixing recommendations for the freeze protection required in your area Recovery Bottle Coolant The recovery bottle is located on the left side of the vehicle 1 Remove the left side panel See page 90 2 Maintain the coolant level between the minimum and maximum marks on the bottle when the fluid is cool 3 Add coolant as needed Recovery Bottle 83 MAINTENANCE Cooling System Radiator Coolant To ensure that the coolant maintains its ability to protect the engine POLARIS recommends that you drain the system completely every two years and add a fresh mixture of antifreeze and water Replace the coolant any time the cooling system has been drained for maintenance or repair If the recovery bottle has run dry check the level in the radiator Add coolant as needed CAUTION Escaping steam can cause burns Never remove the pressure cap
84. p 4 Headlight Lamp Disconnect the harness connector Remove the rubber cover from the back of the headlight Press and turn the locking collar counter clockwise left headlight or clockwise right headlight to release the lamp assembly 5 Install the new lamp Apply a small amount of dielectric grease to the lamp socket or terminals 6 Reverse all steps to reassemble components 98 MAINTENANCE Lights Taillight Lamp Replacement 1 2 Place the transmission in PARK Rotate the taillight socket counter clockwise to remove it Remove the lamp Apply dielectric grease to the socket Install the new lamp Test the lamp for proper operation Reinstall all components in reverse order Front Turn Signal Replacement If a front turn signal light becomes inoperable the lamps cannot be ae gt T F replaced Replace the entire signal lamp assembly Rear Turn Signal Lamp Replacement 1 2 3 Place the transmission in PARK Rotate the turn signal socket counter clockwise to remove it Remove the lamp Apply dielectric grease to the socket Install the new lamp Test the lamp for proper operation Reinstall all components in reverse order 99 MAINTENANCE Spark Plugs Spark Plug Recommendations Refer to the specifications section beginning on page 127 for the recommended spark plug type and gap for your vehicle Torque spark plugs to specification NOTICE Using non
85. pe Cp Main Filter pre filter from the main filter Wash the pre filter in soapy water then rinse and let dry 5 Reinstall the pre filter over the main filter Install a new main filter if needed 6 Reinstall the filter into the air box and tighten the clamp Do not overtighten the clamp as filter damage could occur Breather Valve 7 Reinstall the air box cover and the seat Breather Line 94 MAINTENANCE Breather Valve Hose The breather valve is on the hose that runs between the engine and air box See illustration on page 94 1 2 3 4 5 Remove the left side panel See page 90 Remove the hose clamps from the valve and pull the valve out of the hoses Inspect the valve for debris Blow gently through the valve to check for clogging Replace a damaged or clogged valve Check the hoses for cracks deterioration abrasion or leaks Replace as needed Reinstall the valve and hose clamps NOTICE Operation of your vehicle without a breather valve can cause engine damage Always reinstall the breather valve after removing it for service 95 MAINTENANCE Fuse Replacement If the engine stops or will not Fuse start or if you experience other Box electrical failures a fuse may need replacement Locate and O j correct any short circuits that may have caused the blown fuse then replace the fuse Spare fuses are provided in a compartment on
86. please see your POLARIS dealer for adjustment Throttle Cable Freeplay Adjust throttle cable freeplay at the handlebar 1 2 114 Locate the throttle cable adjuster at the handlebar Squeeze the end of the rubber boot and slide it far enough to expose the end of the inline cable adjuster Loosen the adjuster lock nut Rotate the boot to turn the adjuster until 1 16 to 1 8 1 5 3 mm of freeplay is achieved at the thumb lever While adjusting freeplay be sure to flip the throttle lever back and forth Tighten the lock nut Squeeze the end of the rubber boot and slide it over the cable adjuster to its original position Boot Lock Nut Adjuster MAINTENANCE Cleaning and Storage Washing the Vehicle Keeping your POLARIS vehicle clean will not only improve its appearance but it can also extend the life of various components NOTICE High water pressure may damage components POLARIS recommends washing the vehicle by hand or with a garden hose using mild soap Certain products including insect repellents and chemicals will damage plastic surfaces Do not allow these types of products to contact the vehicle The best and safest way to clean your POLARIS vehicle is with a garden hose and a pail of mild soap and water 1 Use a professional type washing cloth cleaning the upper body first and the lower parts last 2 Rinse with clean water frequently 3 Dry surfaces with a chamois to preven
87. r 1 4 hose and a small plastic squeeze bottle filled with the pre measured amount of oil 2 Reinstall the spark plugs Torque to specification 3 Apply dielectric grease to the inside of the spark plug cap and reinstall the caps onto the plugs 4 Turn the engine over several times using electric start Oil will be forced in and around the piston rings and ring lands coating the cylinder with a protective film of fresh oil 5 If POLARIS fuel system additive is not used the fuel tank fuel lines and injectors should be completely drained of gasoline 119 MAINTENANCE Cleaning and Storage Storage Tips Inspect and Lubricate Inspect all cables and lubricate all areas of the vehicle as recommended in the Periodic Maintenance Chart beginning on page 71 Battery Storage See pages 110 111 for storage and charging procedures Storage Area Covers Set the tire pressure and safely support the ATV with the tires slightly off the ground Be sure the storage area is well ventilated Cover the vehicle with a genuine POLARIS cover Do not use plastic or coated materials They do not allow enough ventilation to prevent condensation and may promote corrosion and oxidation Accessories Auxiliary power outlets provide 12 volt power for operating accessories Accessory outlets are available for all models POLARIS also has a wide range of additional accessories available for your ATV Always install accessories that are approved for ATV
88. r all major repairs The diagnostic mode is accessible only when the check engine warning indicator activates after the key has been turned on Leave the key on if you want to view the active code failure code The diagnostic mode becomes inaccessible if the key is turned off and on and the warning indicator is no longer active This allows the determination of persistent as well as intermittent faults Inactive codes are stored in the history of the unit 34 FEATURES AND CONTROLS Instrument Cluster Digital Analog Gauge Rider Information Center Engine Error Codes Error Code Suspect Parameter The error screen displays Number 0 9 Number SPN only when the CHECK ENGINE light is on or when it goes on and off during one ignition cycle Error codes l are not stored in the gauge when the key is turned off N The code and message is lost but will reappear if the fault reoccurs after restarting the engine If the CHECK ENGINE Failure Mode Indicator FMI light illuminates retrieve the error codes from the display Please see your Polaris dealer for all major repairs 1 Tf the error codes are not displayed use the MODE button to toggle until Ck ENG displays on the main line of the display 2 Press and hold the MODE button to enter the diagnostics code menu 3 Record the numbers displayed in the gear position if any clock and odometer displays 4 Press the MODE button to advance to the nex
89. r other object with your winch Towing an object with a winch produces shock loading of the cable even when towing at slow speeds Towing from a winch also positions the towing force high on the vehicle This can cause instability of the vehicle and possibly lead to an accident 67 WINCH GUIDE Shock Loading 4 Never use recovery straps with your winch Recovery straps are designed to stretch and can store energy This stored energy in the recovery strap is released if a winch cable fails making the event even more hazardous Similarly never use elastic bungie cords for winching 5 Never use the winch to tie down a vehicle to a trailer or other transportation vehicle This type of use also causes shock loading that can cause damage to the winch winch cable or vehicles used Your winch cable is designed and tested to withstand the loads produced by the winch motor when operated from a stationary vehicle Always remember that the winch and winch cable are NOT designed for shock loading 68 WINCH GUIDE Winch Maintenance and Service Safety WARNING Improper or lack of winch maintenance and service could lead to SEVERE INJURY or DEATH Always follow all winch instructions and warnings in this manual 1 Always inspect your winch before each use Inspect for worn or kinked winch cable Also inspect for worn or loose parts including mounting hardware 2 Permit your winch motor to cool down prior to servicing your winch
90. re T2 Shorted to Bus 520224 3 Steering Torque Sensor Full Failure T1 and T2 Shorted to Ground 520225 4 T1 and T2 Shorted to Bus 520225 3 T1 Shorted to Ground amp T2 520225 16 Shorted to Bus T2 Shorted to Ground amp T1 520225 17 Shorted to Bus T1 and T2 are Shorted 520225 2 Steering Position Sensor P1 Partial P1 Shorted to Ground 520226 4 Failure0 P1 Shorted to Bus 520226 3 Steering Position Sensor P2 Partial P2 Shorted to Ground 520227 4 Failure P2 Shorted to Bus 520227 3 Steering Position Sensor Full P1 and P2 Shorted to Ground 520228 4 Failure1 P1 and P2 Shorted to bus 520228 3 EPAS Inverter Temperature Greater than 110 Degrees C 520229 16 Greater than 120 Degrees C 520229 0 EPAS CAN Communications No RX Message for 2 Seconds 520230 9 Receive Error EPAS CAN Communications No TX Message for 2 Seconds 520231 9 Transmit Error Assumes unipolar configuration of stepper motor 37 OPERATION Failure to operate the ATV properly can result in a collision loss of control accident or rollover which may result in serious injury or death Read and understand all safety warnings outlined in the safety section of this owner s manual Break In Period The break in period for your new POLARIS ATV is the first 20 hours of operation No single action on your part is as important as following the procedures for a proper break in Careful treatment of a new engine and drive components w
91. ree operation Purchasing a machine in the crate or without proper dealer set up will void your warranty coverage WARRANTY COVERAGE AND EXCLUSIONS LIMITATIONS OF WARRANTIES AND REMEDIES This POLARIS limited warranty excludes any failures that are not caused by a defect in material or workmanship THIS WARRANTY DOES NOT COVER CLAIMS OF DEFECTIVE DESIGN This warranty also does not cover acts of God accidental damage normal wear and tear abuse or improper handling This warranty also does not cover any vehicle component or part that has been altered structurally modified neglected improperly maintained or used for purposes other than for which it was designed This warranty excludes damages or failures resulting from improper lubrication improper engine timing improper fuel surface imperfections caused by external stress heat cold or contamination operator error or abuse improper component alignment tension adjustment or altitude compensation snow water dirt or other foreign substance ingestion contamination improper maintenance modified components use of aftermarket or unapproved components accessories or attachments unauthorized repairs or repairs made after the warranty period expires or by an unauthorized repair center 129 WARRANTY LIMITATIONS OF WARRANTIES AND REMEDIES This warranty excludes damages or failures caused by abuse accident fire or any other cause other than a defect in materials or workmansh
92. rvice 3 Always apply your vehicle s park brake and or park mechanism to hold the vehicle in place during winching Use wheel chocks if needed Hook Strap A Ae Ca 61 WINCH GUIDE Winch Operation 4 Always use the hook strap when INJURY A handling the hook WARNING Never put your fingers into the hook This could lead to SEVERE Attach the hook itself onto the NO YES load or use a tow strap or chain to secure the load to the winch cable Tip A tow strap is NOT intended to stretch A recovery strap is designed to stretch WARNING Never use a recovery strap when winching due to the excessive energy that can be released if the winch cable breaks This can result in SEVERE INJURY or DEATH See the Shock Loading section on page 67 B Never hook the winch cable back onto itself This will damage the winch cable and may result in winch cable failure WARNING Replace the winch cable at the first sign of damage to prevent SEVERE INJURY or DEATH in the event of failure For your safety always replace POLARIS winch parts including the cable with genuine POLARIS replacement parts available at your authorized POLARIS dealer C 62 If possible keep the winch cable aligned with the centerline of the winching vehicle This will help the spooling of the winch cable and reduce the load on the fairlead If freeing a stuck vehicle by attaching to a tree use an item such as a tow strap to avoi
93. s 1 Do not operate on excessively rough slippery or loose terrain 2 Slow down when entering slippery areas 3 Engage 4X4 before wheels begin to lose traction NOTICE Severe damage to re drive rainmay Sideways Turn in direction occur if the 4X4 is skid of skid engaged while the wheels are TT TT A7 Oe T spinning Allowthe 2 745 44 N gt ST eal rear wheels to stop SS spinning before engaging 4X4 or engage 4X4 before wheels begin to lose traction 4 Be alert Watch the trail Avoid quick sharp turns 5 Never apply the brakes during a skid Correct a skid by turning the handlebars in the direction of the skid and shifting your body weight forward A Always follow the procedures outlined in this manual for operating on slippery or loose surfaces Use extra caution Always avoid skidding or sliding 50 OPERATION Driving Over Obstacles Follow these precautions when operating over obstacles 1 Always check for obstacles before operating in a new area Serious injury or death can result if your vehicle comes in contact with a hidden obstacle 2 Be alert Watch the terrain Use extra caution Never operate over large obstacles ca 4 Avoid hazards such as logs rocks and low branches A Always follow the procedures outlined in this manual for operating over obstacles 51 OPERATION Driving Through Water Maximum Depth Follow these procedures when driving through w
94. s 327 kg 7 based on configuration 731 Ibs 332 kg EPS 7 based on configuration Fuel Capacity 4 5 gal 171 Engine Oil Capacity 2 qts 1 91 Transmission Oil Capacity 32 oz 948 ml Demand Drive Fluid Capacity 9 oz 265 ml Coolant Capacity 2 7 qts 2 5 Front Rack Box Capacity 90 Ibs 40 8 kg Rear Rack Box Capacity 180 Ibs 81 6 kg Receiver Hitch Tongue Capacity 120 Ibs 54 kg Rear rack capacity and tongue weight not to exceed 180 Ibs 81 6 kg Hitch Towing Rating 1225 lbs 555 7 kg Unbraked Trailer Towing Capacity 1786 Ibs 810 kg Overall Length Width Height 83 in 211 cm 48 in 122 cm 48 in 122 cm Wheelbase 50 5 in 128 3 cm Ground Clearance 11 in 28 cm Minimum Turning Radius 65 in 165 cm unloaded Engine Dual overhead cam 4 valve 4 stroke single cylinder Displacement 567 cc Bore x Stroke 99mm x 73 6mm Alternator Output 650 W 7000 RPM Compression Ratio 10 1 Starting System Electric Fuel System Electronic Fuel Injection Ignition System ECU Spark Plug Gap RG6YC 0 7 0 8 mm Lubrication System Wet Sump Driving System Type Automatic PVT POLARIS Variable Transmission Front Suspension MacPherson strut with 8 2 21 cm travel Rear Suspension Progressive rate with 9 5 24 cm travel
95. s Product List 126 Polishing the Vehicle 116 Power Steering 00 23 Power Steering Unit Cleaning 89 Pre Ride Checklist 40 PVT Break In oee cuntaia 39 PVT Dryin 8 eeii reo roseika iea 106 PVE System occ iss acts da die 104 106 R Reverse Operation 54 Reverse Override Switch 20 Rider Information Center 30 35 Riding Gear ts0 cc eeawd ede sce 8 9 S Safety Labels 17 19 Safety Training 8 Safety Winch Maintenance 69 Severe Use sorcscsssusrisei ses 71 Shock Loading the Winch 67 68 Side Panel Removal 90 SIMS Gs nsere r capers Adie dead 46 Signal Words 04 4 Spark Arrester 00 103 Spark Arrester Requirements 70 Spark Plug Inspection 100 101 Spark Plug Recommendations 100 Spark Plug Torque Specification 100 Spark Plugs 100 101 Specifications 127 128 Speedometer 28 Spring Adjustment Rear Shock 113 Starting the Engine 41 Steering Assembly 89 Steering LOCK wo sic ess estes genet 25 Stop Switch soreer orrs is iveta 20 Storage oe 4 stede scsi ware ed nes 115 120 Storage Tips 118 120 Switches 4X4 Switch 000 27 Engine Stop Switch 20 Hazard Warning 21 Headlight Switch 21 OM sena Shue E 21
96. s 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 107 MAINTENANCE Battery Battery Removal Disconnect the battery hold down strap Remove the battery cover if equipped On conventional batteries remove the battery vent tube Disconnect the black negative battery cable first Disconnect the red positive battery cable last Lift the battery out of the ATV Be careful not to tip a conventional battery sideways which could spill electrolyte NOTICE If electrolyte spills immediately wash it off with a solution of one tablespoon baking soda and one cup water to prevent damage to the vehicle De No 108 MAINTENANCE Battery Battery Installation 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 Follow the battery charging instructions on page 111 before installing the battery 2 J Ensure that the battery is fully charged Place the battery in the bat
97. signs of fraying Replace the cable if fraying is i observed shown at right r C Promptly discontinue use of a winch cable in this condition Also replace the winch cable if there are fused or melted fibers Such an area of the synthetic rope will be stiff and appear smooth or glazed Promptly discontinue use of a winch cable in this condition WINCH GUIDE Shock Loading WARNING Your winch cable is very strong but it is NOT designed for dynamic or shock loading Shock loading may tension a winch cable beyond its strength and cause the cable to break The end of a broken winch cable under such high loading can cause SEVERE INJURY or DEATH to you and other bystanders Winch cables are designed to NOT absorb energy This is true of both wire rope and synthetic rope winch cables 1 Never attempt to jerk a load with the winch For example never take up slack in the winch cable by moving the winching vehicle in an attempt to move an object This is a dangerous practice It gener ates high winch cable loads that may exceed the strength of the cable Even a slowly moving vehicle can create large shock loads in a winch cable WARNING SEVERE INJURY or DEATH can result from a broken winch cable 2 Never quickly turn the winch ON and OFF repeatedly jogging This puts extra load on the winch winch cable and generates excessive heat from the motor This is a form of shock loading Never tow a vehicle o
98. sion Oil Recommendations Lubricant Capacity Fill Plug Drain Plug Torque Torque AGL Gearcase Lubricant amp 32 oz 20 25 ft Ibs 20 25 ft Ibs Transmission Fluid 946 ml 27 34 Nm 27 34 Nm 80 MAINTENANCE Transmission Oil Oil Check 1 Position the vehicle on a level surface 2 Remove the fill plug Check the oil level 3 Add the recommended fluid as needed to bring the level to the bottom of the fill hole threads z 4 Reinstall the fill plug Torque to _ specification Fill Plug Fill Level Oil Change 1 2 Se PS Remove the fill plug Place a drain pan under the gearcase Remove the drain plug Allow the oil to drain completely Clean and reinstall the drain plug Torque to specification Add the proper amount of the recommended oil Reinstall the fill plug Torque to specification Check for leaks Dispose of used oil properly 81 MAINTENANCE Front Gearcase Demand Drive Fluid Always check and change the demand drive fluid at the intervals outlined in the Periodic Maintenance Chart beginning on page 71 Maintain the fluid level at the bottom of the fill hole threads See page 126 for the part numbers of POLARIS products Fluid Recommendations Gearcase Lubricant Capacity Fill Plug Drain Plug Torque Torque Front Demand Drive Fluid 9 oz 8 10 ft Ibs 11 ft Ibs Gearcase 265 ml 11 14 Nm 15 Nm The fill plug is located o
99. spect the entire vehicle for possible damage including but not limited to brake throttle and steering systems A Never operate on hills too steep for the vehicle or for your abilities Practice on smaller hills before attempting larger hills Avoid climbing hills steeper than 25 Always follow the procedures outlined in this manual for driving on hills See page 44 A Always follow the procedures outlined in this manual for driving downhill and for braking on hills See page 47 A Always follow the procedures outlined in this manual for crossing the side of a hill See page 46 Never attempt to turn the vehicle around on any hill until you ve mastered on level ground the turning technique outlined in this manual See page 48 13 SAFETY Operator Safety A Always follow the procedures outlined in this manual for braking if you stall or roll backwards while climbing a hill Never back down a hill See page 48 A Always follow the procedures outlined in this manual for operating over obstacles See page 51 A Always follow the procedures outlined in this manual for operating on slippery or loose surfaces Use extra caution Always avoid skidding or sliding See page 50 A Always follow the procedures outlined in this manual for driving through water Never drive through deep or fast flowing water See page 52 14 SAFETY Operator Safety A Always follow the procedures outlined i
100. t error code m Press and hold the MODE button to exit the diagnostics code menu 6 See pages 36 37 for code definitions and failure descriptions Please see your Polaris dealer for all major repairs 35 FEATURES AND CONTROLS Instrument Cluster Diagnostic Display Code Definitions Open Load There is a break in the wires that lead to the item listed in the chart injector fuel pump etc or the item has failed Short to Ground The wire is shorted to ground between the electronic control unit and the item listed in the chart Shorted Load The wires leading to the item listed in the chart are shorted together or the item has shorted internally Short to Battery The wire leading from the item listed in the chart to the electronic control unit is shorted to a wire at battery voltage SPORTSMAN 570 EFI 570 EPS Diagnostic Codes Component Condition SPN FMI Throttle Position Sensor Voltage Too High 51 3 Voltage Too Low 51 4 Engine Temperature Sensor Voltage Too High 110 3 Voltage Too Low 110 4 Temperature Too High 110 16 Engine Overheat Shutdown 110 0 Intake Air Temperature Sensor Voltage Too High 105 3 Voltage Too Low 105 4 Manifold Absolute Pressure Sensor Voltage Too High 102 3 Voltage Too Low 102 4 Crankshaft Position Sensor Circuit Fault 636 8 Gear Sensor Signal Voltage Too Low to Calibrate 523 4 Voltage Too High 523 3 Si
101. t water spots Washing Tips e Avoid the use of harsh cleaners which can scratch the finish e Do not use a power washer to clean the vehicle e Do not use medium to heavy duty compounds on the finish e Always use clean cloths and pads for cleaning and polishing Old or reused cloths and pads may contain dirt particles that will scratch the finish 115 MAINTENANCE Cleaning and Storage Washing the Vehicle If a high pressure water system is used for cleaning not recommended exercise extreme caution The water may damage components and could remove paint and labels Avoid directing the water stream at the following items e Wheel bearings e Radiator e Transmission seals e Brakes e Cab and body panels e Electrical components e Switches and controls e Labels If an informational or graphic label becomes illegible or comes off contact your POLARIS dealer to purchase a replacement Replacement safety labels are provided by POLARIS at no charge Grease all zerk fittings immediately after washing Allow the engine to run for a while to evaporate any water that may have entered the engine or exhaust system Polishing the Vehicle POLARIS recommends the use of common household aerosol furniture polish for polishing the finish on your POLARIS vehicle Follow the instructions on the container Polishing Tips e Avoid the use of automotive products some of which can scratch the finish of your vehicle e Always
102. tery holder With conventional batteries install the battery vent tube sealed batteries do not have a vent tube The vent tube must be free of obstructions and securely installed Route the tube away from the frame and vehicle body to prevent contact with electrolyte WARNING Battery gases could accumulate in an improperly installed vent tube and cause an explosion resulting in serious injury or death Always ensure that the vent tube is free of obstructions and is securely installed as recommended 4 O GO TN On conventional batteries coat the terminals with dielectric grease or petroleum jelly Connect and tighten the red positive cable first Connect and tighten the black negative cable last Install the battery cover if equipped Secure the battery hold down strap Verify that cables are properly routed Cables should be safely tucked away at the front and rear of the battery 109 MAINTENANCE Battery Battery Storage Whenever the vehicle is not used for a period of three months or more remove the battery from the vehicle ensure that it s fully charged and store it out of the sun in a cool dry place Check battery voltage each month during storage and recharge as needed to maintain a full charge Tip Power plug leads may need to be bent down so that the battery cover can be installed POLARIS recommends maintaining battery charge by using a POLARIS Battery Tender charger or by charging about once a month t
103. to disengage the under seat fasteners 3 Remove the seat 89 MAINTENANCE Side Panel Removal 1 2 90 Remove the seat See page 89 Use a flat screwdriver to remove the plastic rivets securing the side panel Grasp the rear of the side panel near the rear cab With a firm motion pull the side panel outward to disengage the side panel from the grommets Pull the panel outward and rearward to remove it Step 2 Step 3 MAINTENANCE Footwell Removal 1 Remove the four screws on the bottom of the footwell 2 Use a flat screwdriver to remove the plastic rivets securing the footwell to the fenders 3 Remove the footwell Plastic Rivets Torx Head Screws 91 MAINTENANCE Tires A WARNING Operating your ATV with worn tires improperly inflated tires non standard tires or improperly installed tires will affect vehicle handling and could cause an accident resulting in serious injury or death Always follow all tire maintenance procedures as outlined in this manual and on the labels on the vehicle Always use original equipment size and type when replacing tires Refer to the specifications section beginning on page 127 for recommended tire type size and pressure Tire Tread Depth R Always replace tires 1 8 3 mm when tread depth is worn to 1 8 3 mm or less p WS Front Wheel Hub Tightening Front wheel bearing tightness and spindle nut retention are critical component operatio
104. ts cables etc D Throttle Cable 50 H 6M 500 800 Inspect adjust lubricate Release Switch replace if necessary Throttle Body 50 H 6M 500 800 Inspect duct for proper Intake Duct sealing air leaks Drive belt 50 H 6M 500 800 Inspect adjust replace as needed Cooling system 50 H 6M 1000 1600 Inspect coolant strength seasonally pressure test system yearly gt Engine oil change 100 H 6M 1000 1600 Change the oil and filter gt Oil lines and 100 H 6M 1000 1600 Inspect for leaks and loose fasteners fittings T3 MAINTENANCE Periodic Maintenance Chart Item Maintenance Interval Remarks whichever comes first Hours Calendar Miles Km gt Demand drive fluid 100 H 12M 1000 1600 Change fluid normal use gt Rear gearcase oil 100 H 12M 1000 1600 Change fluid gt Transmission oil 100 H 12M 1000 1600 Change fluid D Valve clearance 100 H 12M 1000 1600 Inspect adjust D Fuel system filter 100 H 12M 1000 1600 Check for leaks at tank cap lines filter pump replace lines every two years gt Radiator if 100 H 12M 1000 1600 Inspect clean external applicable surfaces gt Cooling hoses if 100 H 12M 1000 1600 Inspect for leaks applicable gt Engine mounts 100 H 12M 1000 1600 Inspect Exhaust muffler 100 H 12M 1000 1600 Inspect pipe D Spark plug 100 H 12M 1000 1
105. ually while in reverse 4X4 AWD Caution CAUTION Do not push switch to engage 4X4 AWD if the rear wheels are spinning This may cause severe drive shaft and clutch damage 19 FEATURES AND CONTROLS Switches Engine Stop Switch The engine will not start or run when the switch is in the D OFF position eA 5 i oot Y bg a OFF O Engine E g St ee Headlight Sitch Push the stop switch down to Switch stop the engine quickly Pull the stop switch up to the RUN position before attempting to start the R Hazard everse engine Override Switch Both the main switch and the Switch J engine stop switch will shut S Turn off all electrical power to the Horn Signal vehicle including lights Switch Switch Mode Reverse Override Switch This vehicle is equipped with a reverse speed limiter system To gain additional wheel speed while backing release the throttle and depress the override switch A Pressing the override switch while the throttle is open can cause loss of control which may result in serious injury or death Always release the throttle before pressing the override switch The reverse override button also acts as a MODE button when held down for approximately one half second See the instrument cluster information beginning on page 28 The transmission cannot be in reverse when using the override button as a MODE button 20 FEATURES AND CONTROLS Switches Headlight Switch Th
106. uch as ambient noise or temperature SAFETY Safety Training Never operate this vehicle without proper instruction Take a training course For more information about safety contact an authorized POLARIS dealer or visit the POLARIS web site at www polaris com Safe Riding Gear Always wear appropriate clothing when riding an ATV Wear protective clothing for comfort and to reduce the chance of injury Helmet Eye ORO ey Helmet Wearing a helmet can prevent a severe head injury Whenever riding a POLARIS vehicle always wear a helmet that meets or exceeds established safety standards Approved helmets in the USA and Canada bear a U S Department of Transportation DOT label Approved helmets in Europe Asia and Oceania bear the ECE 22 05 label The ECE mark consists of a circle surrounding the letter E followed by the distinguishing number of the country which has 051039 granted approval The approval number and serial 0006 31 number will also be displayed on the label SAFETY Safe Riding Gear Eye Protection Do not depend on eyeglasses or sunglasses for eye protection Whenever riding a POLARIS vehicle always wear shatterproof goggles or use a shatterproof helmet face shield POLARIS recommends wearing approved Personal Protective Equipment PPE bearing markings such as VESC 8 V 8 Z87 1 or CE Make sure protective eye wear is kept clean Gloves Off road style gloves with knuckle pads are the best
107. use clean cloths and pads for cleaning and polishing Old or reused cloths and pads may contain dirt particles that will scratch the finish 116 MAINTENANCE Cleaning and Storage Chrome Wheel Care if equipped Proper maintenance will protect chrome wheels from corrosion preserve wheel life and ensure a like new appearance for many years Chrome wheels exposed to road salt or salt in the air in coastal areas are more susceptible to corrosion if not properly cleaned Clean chrome wheels more often if they re exposed to salt or other corrosive elements 1 Wash chrome wheels frequently Use a mild detergent Never use abrasive cleaners on plated or painted surfaces 2 Rinse well with clear water Soap detergents salt dirt mud and other elements can cause corrosion 3 Polish the clean chrome wheels periodically Use an automotive grade chrome polish 4 Routinely and liberally apply a weather resistant wax to each polished chrome wheel Choose a product suitable for chrome finishes Read and follow the product labels and instructions Removing Corrosion If light rust is found on the chrome finish use steel wool 0000 OTT grade to remove it Gently rub the affected areas with the steel wool until the corrosion has been removed Clean and polish the wheel as outlined above 117 MAINTENANCE Cleaning and Storage Storage Tips NOTICE Starting the engine during the storage period will disturb the protective film cr

Polaris 525 IRS Offroad Vehicle User Manual

Contents

Download Pdf Manuals

Related Search

Related Contents