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Polaris 500 HO Offroad Vehicle User Manual

1. 87 Engine Qil 84 85 Rear Gearcase 89 Transmission Oil 86 F Fluid Level ADCS vx eA a 90 Brakes lel 32 34 Coolant Bottle 93 Demand Drive 87 Engine Oil 83 Radiator sieni testes pes 94 Rear Gearcase 88 Transmission Oil 86 Foot Brake Auxiliarv 34 Footwell Removal 97 Front Compartment 42 Front Gearcase Demand Drive 87 Front Rack Compartment 42 Fuel Recommendations 39 Fuel Safety 0000 11 Fuel Tank Cap 000 39 Fuse Replacement 101 G Gasoline Handling 11 Gear Selector 35 Gearcase Oil Rear 88 89 GIVES da toa Beas dee A a na 9 H Hand Brake 95 Handlebar Adjustment 120 Hauling Cargo 72 75 Headlight Housing Replacement 104 Headlight Lamp Replacement 102 Headlight Switch 29 Helmet duse emere e 8 High Beam Adjustment 103 High Range Use 111 Hub Tightening 98 l Idle RPM Adjustment 118 Immersion Maintenance 108 Instrument Cluster 43 51 K Key Switch 00000 29 K Turn uode a wes 66 67 INDEX L Lights es ea 102 105 Headlight Replacement 104 Headlight Lamp 102 High Beam Adjustment 103 Low Beam
2. 133 Specifications 22022242 4402ca 22044084 134 Declaration of Conformity 136 Warranty Libi eimbrijzzjota 6 06054 ta bi 137 Maintenance Log ssss 145 Index Li 6 ct ee aud ta tee ee seas nis 148 INTRODUCTION The following signal words and svmbols appear throughout this manual and on your vehicle Your safety is involved when these words and sym bols are used Become familiar with their meanings before reading the manual A The safetv alert svmbol indicates a potential personal injurv hazard WARNING A WARNING indicates a hazardous situation which if not avoided may result in death or serious injury CAUTION A CAUTION indicates a hazardous situation which if not avoided may result in minor or moderate injury NOTICE A NOTICE indicates a situation that may result in property damage The Prohibition Safety Sign indicates an action NOT to take in order to avoid a hazard The Mandatory Action Sign indicates an action that NEEDS to be taken to avoid a hazard INTRODUCTION Failure to heed the warnings and safetv precautions contained in this manual can result in severe injurv or death A Polaris ATV is not a tov and can be hazardous to operate This vehicle handles differentiv than other vehicles such as motorcvcles and cars A collision or rollover can occur quickiv even during routine maneuvers like turning or driving on hills or over obstacles if vou fail to take proper
3. DATE MILES KM OR HOURS TECHNICIAN SERVICE PERFORMED COMMENTS 146 MAINTENANCE LOG DATE MILES KM OR HOURS TECHNICIAN SERVICE PERFORMED COMMENTS 147 INDEX 0 9 4X4 Switch LL 29 A Access Front Compartment 42 Accessories L 128 Active Descent Control Fluid 90 91 Active Descent Control System 38 ADC System LL 000 38 Air Filter 6 0 0 100 All Wheel Drive System 36 37 Auxiliary Foot Brake 95 B Battery 0 cece wees 112 117 Charging Conventional 116 Charging Sealed 116 117 Fluid Conventional 115 Installation 114 Removal 113 SLOFABEL kos si RE 115 BEITA enie o eere SE 35 Boots 4 24553 A eot re eie 9 Brake Fluid Auxiliary Foot Brake 34 Brake Fluid Main Brake System 32 Brake Lever 0 00000 31 Brake Foot 0000 34 95 Brake Hand Lever 95 Brake Parking 33 Brakelight Lamp Replacement 105 Brakes mi ata 95 Break In Period 52 53 C Camber Adjustment 121 CarBO S IS eee es RC ee 73 75 Cargo Loading Lus 72 Caster Adjustment 121 Chrome Wheel Care 125 Cleaning and Storage 123 128 Clothing aile 9 Clutching 2 22222 m a 135 Cold Weather Operation
4. Starting out going up a steep incline Use low range or turn around using the K turn see page 66 Driving at low RPM or ground speed 3 7 MPH Drive at a higher speed or use low range more frequently See page 111 Insufficient warm up at low ambient tempera tures Warm the engine at least 5 minutes With the transmission in neutral advance the throttle to about 1 8 throttle in short bursts 5 to 7 times The belt will become more flex ible and prevent belt burning Slow easy clutch engage ment Use the throttle quickly and effectively Towing pushing at low RPM low ground speed Use low range only Utility use plowing Use low range only Stuck in mud or snow Shift the transmission to low range and carefully use fast aggressive throttle application to engage clutch WARNING Excessive throttle may cause loss of control and vehicle overturn Climbing over large objects from a stopped position Shift the transmission to low range and carefully use fast brief aggressive throttle application to engage clutch WARNING Excessive throttle may cause loss of control and vehicle overturn Belt slippage from water or snow ingestion into the PVT system Dry out the PVT See page 111 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 t
5. Balance your weight carefully Avoid sudden movements Maintain a steady rate of speed Do not make sudden turns or stops Do not make sudden throttle changes 68 OPERATION Driving Over Obstacles Follow these precautions when operating over obstacles 1 2 Always check for obstacles before operating in a new area Look ahead and learn to read the terrain Be constantly alert for haz ards such as logs rocks and low hanging branches Travel slowly and use extra caution when operating on unfamiliar terrain Not all obstacles are immediately visible Never attempt to operate over large obstacles such as rocks or fallen trees Always have a passenger dismount before operating over an obsta cle that could cause a fall from the vehicle or vehicle tipover 69 OPERATION Driving in Reverse 1 SO Gnome oe me MOMS Follow these precautions when operating in reverse Always check for obstacles or people behind the vehicle Be aware that a passenger can obstruct your view Always avoid backing downhill Back slowly Apply the brakes ightly for stopping Avoid turning at sharp angles Never open the throttle suddenly Do not use the override switch unless additional wheel speed is required for vehicle movement Use the override with caution as rearward vehicle speed is greatly increased Do not operate at wide open throttle Operate the throttle just enough to maintain a desired speed NOTICE
6. 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 112 MAINTENANCE Batterv Your ATV may have either a sealed battery which requires little mainte nance or a conventional battery A sealed battery can be identified by its flat covers on the top of the battery A conventional battery has six filler caps on the top of the battery Always keep battery terminals and connections free of corrosion If cleaning is necessary remove corrosion with a stiff wire brush Wash with a solution of one tablespoon baking soda and one cup water Rinse well with tap water and dry off with clean shop towels Coat the termi nals with dielectric grease or petroleum jelly Be careful not to allow cleaning solution or tap water into a conventional battery Battery Removal 1 Remove the seat 2 Disconnect the black negative battery cable first Disconnect the red positive battery cable last 3 Disconnect the bat
7. Headlight 1 Single Beam on Headlight Pod 50 watt 2 Single Beam on Bumper 50 watt Taillights 8 26 watts Brake Light 27 watts Instrument Cluster Digital LCD LED Clutching Altitude Shift Drive Clutch Driven Helix Weight Spring Clutch Spring Meters 0 1800 23 58 Red Black Red White 52 60 BA 500 Feet 0 6000 PN 1322911 PN 7043500 PN 3234621 PN 3234919 1800 3700 23 54 Red Black Red White 52 60 BA 500 6000 12000 PN 1322914 PN 7043500 PN 3234621 PN 3234919 EBS models require no helix spring adjustment 135 DECLARATION OF CONFORMITV Polaris Industries Inc 2100 Hwy 55 Medina MN 55340 U S A Telephone 763 542 0500 We Polaris Industries Inc declare that the vehicles listed below conform to the essential health and safetv requirements applicable to off road all terrain vehicles APPLICABLE EUROPEAN DIRECTIVES TEST EVALUATION METHODS 98 37 EC as amended Machinery Directive EN 1050 hazard analysis CD 77 311 EEC driver perceived noise level 2004 108 EC as amended EMC Directive CISPR 12 2001 CAN CSA C108 4 M92 EN 55012 2002 EN 61000 6 2 2001 PRODUCT IDENTIFICATION VEHICLE SERIES TRADE NAME MODEL SOUND YEARS PRESSURE dB A KA05 OUTLAW 50 2008 2009 2010 76 8 KAO OUTLAW 90 2008 2009 2010 76 8 FA09 SPORTSMAN 90 2008 2
8. MAINTENANCE Cleaning and Storage Washing the Vehicle If a high pressure water system is used for cleaning not recommended exercise extreme caution The water may damage components and could remove paint and labels Avoid directing the water stream at the follow ing items Wheel bearings Electrical components Radiator Switches and controls Transmission seals Fuel system components Cab and body panels Labels and decals If an informational or graphic label becomes illegible or comes off con tact your Polaris dealer to purchase a replacement Replacement safety labels are provided by Polaris at no charge Grease all zerk fittings immediately after washing Allow the engine to run for a while to evaporate any water that may have entered the engine or exhaust system Polishing the Vehicle Polaris recommends the use of common household aerosol furniture polish for polishing the finish on your Polaris vehicle Follow the instructions on the container Polishing Tips Avoid the use of automotive products some of which can scratch the finish of your vehicle Always use clean cloths and pads for cleaning and polishing Old or reused cloths and pads may contain dirt particles that will scratch the finish 124 MAINTENANCE Cleaning and Storage Chrome Wheel Care if equipped Proper maintenance will protect chrome wheels from corrosion pre serve wheel life and ensure a like new appearance for many
9. NOTICE Severe damage to drive train may occur if the 4X4 is engaged while the wheels are spinning Allow the rear wheels to stop spinning before engaging 4X4 or engage 4X4 before wheels begin to lose traction 4 Maintain a high level of alertness reading the trail and avoiding quick sharp turns which can cause skids 5 Never apply the brakes during a skid Correct a skid by turning the handlebars in the direction of the skid and shifting your body weight forward 62 OPERATION Driving Uphill Braking and handling are greatly affected when operating in hillv ter rain Improper procedure could cause loss of control or overturn When ever traveling uphill follow these precautions 1 Never operate in TURF mode while operating on a hill or other irregular terrain Always move the 4X4 switch to ADC 4X4 before ascending or descending a hill See page 38 Drive straight uphill Avoid steep hills 15 maximum Always check the terrain carefully before ascending any hill Never climb hills with excessively slippery or loose surfaces Keep both feet on the footrests Shift body weight uphill A passenger should also shift body weight uphill ol OY SA woe MD 8 Proceed at a steady rate of speed and throttle opening Opening the throttle suddenly could cause the ATV to flip over backwards 9 Never go over the top of any hill at high speed An obstacle a sharp drop or another vehicle or person could be on the other side
10. Never operate the ATV on a frozen bodv of water Poor Visibilitv Operating the ATV in darkness or inclement weather could result in a collision or accident especiallv if operating on a road or street This ATV is not equipped with highwav approved lights Operate this vehicle off road oniv Use caution and drive at reduced speeds in conditions of reduced visibilitv such as fog rain and darkness Clean headlights frequently and replace burned out headlamps promptly 20 SAFETV Safetv Warnings Operating a Damaged ATV Operating a damaged ATV can result in an accident After anv overturn or accident have a qualified service dealer inspect the entire machine for possible damage including but not limited to brakes throttle and steering svstems Physical Skills Safe operation of this rider active vehicle requires good judgement and phvsical skills Persons with cognitive or phvsical disabilities who operate this vehicle have an increased risk of overturn and loss of control Never secure a passenger to the vehicle or to the operator with a belt rope or similar device Hot Exhaust Svstems Exhaust svstem components are verv hot during and after use of the vehicle Hot components can cause burns and fire Do not touch hot exhaust svstem components Alwavs keep combustible materials awav from the exhaust system Use caution when traveling through tall grass especially dry grass Unauthorized Use of the ATV Leaving the keys
11. Pantone 426c Sportsman X2 JJO EFI Owner s Manual for Maintenance and Safetv Read this manual carefully It contains important safety information This is an adult vehicle only Operation is prohibited for those under 16 years of age A WARNING The engine exhaust from this product contains chemicals known to the State of California to cause cancer birth defects or other reproductive harm A card containing important ATV safetv information should be attached to the owner s manual on the next page If you cannot locate this card or if it has been removed please call 1 800 342 3764 for assistance OD RECYCLED The text is printed on 10096 recycled with 4096 post consumer waste PCW Pantone 426C 2 AWARNING Improper vehicle use can result in SEVERE INJURY or DEATH ea ALWAYS USE NEVER USE NEVER CARRY NEVER USE AN APPROVED ON PUBLIC MORE THAN WITH DRUGS HELMET AND ROADS 1 PASSENGER OR ALCOHOL PROTECTIVE GEAR FOR DRIVER AND PASSENGER NEVER operate e without proper ATV training or instruction e at speeds too fast for your skills or the conditions e on public roads a collision can occur with another vehicle e with a passenger unless passenger seat is securely in place THE OPERATOR MUST ALWAYS use proper riding techniques to avoid overturns on hills and rough terrain and in turns avoid paved surfaces pavement may seriously affect handling and control e reduce speed
12. Tip 10 11 12 13 Fuel Gauge The segments of the fuel gauge show the level of fuel in the fuel tank When the last segment clears a low fuel warning is activated All segments including the fuel icon will flash Refuel immediately If the fuel icon fails to display an open or short circuit has occurred in the fuel sensor circuit See your dealer High Beam Indicator This indicator appears when the lights are set to high beam Clock 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 dis play for 5 10 seconds See page 48 for resetting instructions Engine Overheat Warning This indicator flashes to indicate an overheated engine If the indicator stops flashing but remains illu minated the overheating condition remains and the system will automatically reduce engine power Service Indicator 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 48 for resetting instructions Under Over Voltage This warning usually indicates that the ATV is operating at an RPM too low to keep the battery charged It may also occur when the engine is at idle and high electrical load lights cooling fan accessories is applied Drive at a higher RPM or recharge the battery to clear the warning Check Engine Warning Indicator This
13. gt ADC fluid 200 H 24M 2000 3200 Change every two years a every 25 hours if extreme use conditions see page 90 Spark arrestor 300 H 36M 3000 4800 Clean out E Valve clearance 1000 H 10000 Inspect adjust E 16000 E 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 E Emission Related Service W Have an authorized Polaris dealer perform these services 80 MAINTENANCE Lubrication Guide Check and lubricate all components at the intervals outlined in the Peri odic Maintenance Chart beginning on page 77 Items not listed in the chart should be lubricated at the General Lubrication interval The a arms and upper control arms are lubricated at the factorv and no additional lubrication will be needed However if these components are subjected to severe use grease zerks have been provided for additional lubrication at the user s discretion Item Recommended Capacity Fill Plug Drain Plug Inspection Lubricant at Fluid Torque Torque Procedure Change Engine Oil PS 4 PLUS 2 qt 15 17 ft Ibs Page 82 Performance 1 9 1 20 23 Nm Synthetic 2W 50 Transmission Synthetic 320z 10 14 ft Ibs 10 14 ft Ibs Page 86 Oil Sportsman XP 950 ml 14 19 Nm 14 19 Nm Transmission Fluid Demand Drive Demand Drive 9 3 oz 8 10 ft I
14. in the raised position 75 EMISSION CONTROL SVSTEMS Noise Emission Control Svstem Do not modify the engine intake or exhaust components as doing so may affect compliance with U S A EPA noise control requirements 40 CFR 205 and local noise level requirements Operation on Public Lands in the U S A Your Polaris vehicle has a spark arrestor that was tested and qualified to be in accordance with the USFS standard 5100 1c Federal law requires that this spark arrestor be installed and functional when the vehicle is operated on public lands Operation of off road vehicles on public lands in the U S A is regulated by 43 CFR 420 Violations are subject to monetary penalties Federal regulations can be viewed online at www gpoaccess gov ecfr Crankcase Emission Control System This engine is equipped with a closed crankcase system Blow by gases are forced back to the combustion chamber by the intake system All exhaust gases exit through the exhaust system Exhaust Emission Control System Exhaust emissions are controlled by engine design An electronic fuel injection EFI system controls fuel delivery The engine and EFI com ponents are set at the factory for optimal performance and are not adjustable The vehicle compliance labels can be found on the frame tubing of the vehicle Electromagnetic Interference This spark ignition system complies with Canadian ICES 002 This vehicle complies with the EMC requirements of Euro
15. 0z 89 ml cartridge 2871423 Premium All Season Grease 14 0z 414 ml cartridge 2871460 Starter Drive Grease 2871515 Premium U Joint Lube 3 0z 89 ml cartridge 2871551 Premium U Joint Lube 14 0z 414 ml cartridge 2871329 Dielectric Grease Nyogel 2872073 Chain Lube Aerosol 6 25 0z 185 ml 2872348 Chain Lube Aerosol 16 0z 473 ml Additives Miscellaneous 2871326 Carbon Clean Plus 2870652 Fuel Stabilizer 2872189 DOT 4 Brake Fluid 2871956 LoctiteTM 565 Thread Sealant 2859044 Polaris Battery Tender Charger 133 SPECIFICATIONS Sportsman X2 550 EFI Maximum Weight Capacitv 735 Ibs 333 kg includes operator passenger cargo accessories Dry Weight 799 bs 362 4 kg Fuel Capacity 5 25 gal 20 1 Engine Oil Capacity 2 qts 1 9 1 Coolant Capacitv 2 qts 1 91 Transmission Oil Capacitv 32 oz 948 ml Demand Drive Fluid Capacitv 9 3 oz 275 ml Rear Gearcase Oil Capacitv 6 1 oz 180 ml Front Rack Storage Box Capacitv 120 Ibs 54 kg Rear Storage Box Capacitv 400 Ibs 181 kg Hitch Tongue Weight 150 Ibs 68 kg Rear box capacity and tongue weight not to exceed 400 Ibs 181 kg Hitch Towing Rating 1500 Ibs 680 kg on level ground Unbraked Trailer Towing Capacity 1995 Ibs 905 kg Overall Length 93 25 in 237 cm Overall Width 47 6 in 121 cm
16. 18 19 20 2 Place shop towels beneath the oil fil ter Using an oil filter wrench avail able from your Polaris dealer turn the filter counterclockwise to remove it Using a clean dry cloth clean the filter sealing surface on the crank case Lubricate the o ring on the new fil ter 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 Oil Filter gasket contacts the sealing surface then turn it an additional 1 2 turn Remove the dipstick Add the proper amount of the recommended oil Do not overfill Reinstall the dipstick Place the transmission in PARK Lock the parking brake Start the engine Allow it to idle for one to two minutes Stop the engine Check for leaks Check the oil level Add oil as needed to bring the level to the upper mark on the dipstick Dispose of used filter and oil properly 85 MAINTENANCE Transmission Oil Polaris recommends the use of Polaris Synthetic Sportsman XP Trans mission Fluid for this transmission See the table on page 81 for fluid recommendations capacities and plug torques Always check and change the transmission oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 77 See page 133 for the part numbers of Polaris products Maintain the oil level at the bot tom of the fill plug hole The fill plug is located on the ri
17. 40 FEATURES AND CONTROLS Passenger Seat Seat Conversion 5 Liftthe adjustment latch at the top of the passenger backrest Raise the backrest to the desired position Release the latch making sure it locks into one of the three operating positions The backrest must be moved out of the lowest position before it can be secured in the upright position The lowest position is for seat storage only Do not leave the backrest in the lowest position Always adjust the backrest to one of the three operating positions 6 Lower the operator backrest to create the Backrest Adjustment passenger seat Two Latch retaining pins under the seat should fit into the two Passenger grommets on the seat base Ti 7 Test the passenger seat lock out by attempting to release the cargo box dump lever If the dump lever releases the seat is not secure Repeat the set up procedure If the lock out is not working properly do not allow a passenger to ride the vehicle See your Polaris dealer for service 8 To return the vehicle to single rider operation reverse all steps Always Locked lower the passenger backrest to the lowest position before folding it down into the cargo box Turn the operator backrest latches 1 4 turn to secure the locks 41 FEATURES AND CONTROLS Front Rack Compartment Release the front rack latches Latches and remove the rack to gain access to the front compart ment To reinstall the rack hold th
18. Safety Labels 22 27 Age 16 Warning 23 AWD Caution 23 Box Warning 27 Clutch Cover Warning 26 Discretionary Warning 24 General Warning 22 Passenger Safety Warning 24 Rack Warning Front and Rear 26 Reverse Override Warning 23 Tire Pressure Load Warning 25 Safety Training 7 Safety Warnings 10 21 Age Restrictions 10 Carrying a Passenger 12 Carrying Multiple Passengers 12 Crossing Hillsides 15 Deep Water 19 Descending Hills Improperly 15 Excessive Speeds 13 Exhaust Exposure 11 Failure to Inspect 11 150 S Safety Warnings Frozen Bodies of Water 20 Handling Gasoline 11 Hot Exhaust Svstems 21 Improper Cargo Loading 19 Improper Hill Climbing 15 Improper Tire Maintenance 18 Jumps and Stunts 14 Operating a Damaged ATV 21 Operating on Pavement 13 Operating on Public Roads 13 Operating on Steep Hills 16 Operating Over Obstacles 18 Operating Without Instruction 10 Passenger in the Cargo Box 13 Physical Control of the ATV 14 Physical Skills 21 Poor Visibility 20 Protective Apparel 12 Reverse Operation 17 Skidding or Sliding 18 Slippery Terrain 17 Stalling Whi
19. 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 Signal 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 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 Assumes unipolar configuration of stepper motor 51 OPERATION Failure to operate the ATV properly can result in a collision loss of c
20. WARRANTV Exported Vehicles How to Get Service If Purchased From A Private Partv If you purchase a Polaris product from a private citizen to be kept and used outside of the country in which the vehicle was originally purchased all warranty coverage will be denied Notice If your vehicle is registered outside of the country where it was purchased and you have not followed the procedure set out above your vehicle will no longer be eligible for war ranty or service bulletin coverage of any kind Vehicles registered to Government offi cials or military personnel on assignment outside of the country where the vehicle was purchased will continue to be covered by the basic warranty For questions call Polaris Customer Assistance United States 1 888 704 5290 Canada 1 204 925 7100 142 WARRANTV U S A EPA Emissions Limited Warrantv This emissions limited warranty is in addition to the Polaris standard limited warranty for your vehicle Polaris Industries Inc warrants that at the time it is first purchased this emissions certified vehicle is designed built and equipped so it conforms with applica ble U S Environmental Protection Agency emission regulations Polaris warrants that the vehicle is free from defects in materials and workmanship that would cause it to fail to meet these regulations The warranty period for this emissions certified vehicle starts on the date the vehicle is first purchased and continues for a period
21. battery with a charging output no larger than 1 10 of the battery s amp hr rating Charge as needed to raise the specific grav ity to 1 270 or greater 3 Reinstall the battery See page 114 Make sure the positive terminal is toward the front of the vehicle Battery Charging Sealed Battery The following battery charging instructions apply only to the installa tion of a sealed battery Read all instructions before proceeding with the installation of this battery The sealed battery is already filled with electrolyte and has been sealed and fully charged at the factory Never pry the sealing strip off or add any other fluid to this battery The single most important thing about maintaining a sealed battery is to keep it fully charged Since the battery is sealed and the sealing strip cannot be removed you must use a voltmeter or multimeter to measure DC voltage WARNING An overheated battery may explode causing severe injury or death Always watch charging times carefully Stop charging if the battery becomes very warm to the touch Allow it to cool before resuming charging For a refresh charge follow all instructions carefully 1 Check the battery voltage with a voltmeter or multimeter A fully charged battery will register 12 8 V or higher 2 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
22. cable last 7 Verify that cables are properly routed Cables should be safely tucked away at the front and rear of the battery 8 Install the seat 114 MAINTENANCE Batterv Batterv Storage Whenever the vehicle is not used for a period of three months or more remove the batterv from the vehicle ensure that it s fullv charged and store it out of the sun in a cool drv place Check batterv voltage each month during storage and recharge as needed to maintain a full charge Tip Power plug leads may need to be bent down so that the battery cover can be installed Polaris recommends maintaining battery charge by using a Polaris Bat tery Tender charger or by charging about once a month to make up for normal self discharge Battery Tender can be left connected during the storage period and will automatically charge the battery if the voltage drops below a pre determined point See page 133 for the part numbers of Polaris products Battery Fluid Conventional Battery A poorly maintained battery will 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 115 MAINTENANCE Batterv Batterv Charging Conventional Batterv 1 Remove the battery from the vehicle to prevent damage from leak ing or spilled electrolyte during charging See page 113 2 Charge the
23. hold on to the operator Turning Improperly Turning improperly could cause loss of traction loss of control accident or overturn Always follow proper procedures for turning as described in the owner s manual Practice turning at slow speeds before attempting to turn at faster speeds Never turn at excessive speed Jumps and Stunts Attempting wheelies jumps and other stunts increases the risk of an accident or overturn Never attempt wheelies jumps or other stunts Avoid exhibition driving 14 SAFETV Safetv Warnings Improper Hill Climbing Improper hill climbing could cause loss of control or overturn Alwavs follow proper procedures for climbing hills as described in the owner s manual See page 63 Never operate in TURF mode while operating on a hill or other irregular terrain Alwavs move the 4X4 switch to ADC 4X4 before ascending or descending a hill See page 38 Descending Hills Improperly Improperly descending a hill could cause loss of control or overturn Always follow proper procedures for traveling down hills as described in the owner s manual See page 65 Always descend a hill with the transmission in forward gear Do not descend a hill with the transmission in neutral Never operate in TURF mode while operating on a hill or other irregular terrain Always move the 4X4 switch to ADC 4X4 before ascending or descending a hill See page 38 Crossing Hillsides Driving on a
24. in an accident Maintain brake fluid at the recommended level Do not overfill Never store or use a partial bottle of brake fluid Brake fluid is hygroscopic meaning it rapidly absorbs moisture from the air The moisture causes the boiling temperature of the brake fluid to drop which can lead to early brake fade and the possibility of brake failure which could result in an accident After opening a bottle of brake fluid always discard any unused portion Check the brake fluid in the master cylinder before each ride 1 Position the ATV on a level surface 2 Position the handlebars so the master cylinder is level 3 View the brake fluid level through the indicator window on the top of the master cylin Indicator der The eye will appear dark Window when the fluid level is full When fluid is low the eye will be clear 4 Ifthe fluid level is low add DOT 4 brake fluid only Do not overfill Master Cylinder 32 FEATURES AND CONTROLS Parking Brake Locking the Parking Brake 1 2 3 4 5 Place the transmission in PARK Y Squeeze and release the brake G A lever two or three times then o squeeze and hold I E Push the parking brake lock forward to engage the lock Release the brake lever To release the parking brake lock squeeze and release the brake lever It will return to its unlocked position WARNING Operating the ATV while the parking brake is engaged could resu
25. in the ignition can lead to unauthorized use of the vehicle which could result in an accident or overturn Always remove the ignition key when the vehicle is not in use 21 SAFETV Safetv Labels and Locations Warning labels have been placed on the vehicle for vour protection Read and follow the instructions on each label carefully If any of the labels shown in this manual differ from the labels on your vehicle always read and follow the instructions of the labels on the vehicle If an informational or graphic label becomes illegible or comes off con tact your Polaris dealer to purchase a replacement Replacement safety labels are provided by Polaris at no charge The part number is printed on the label General Warning WARNING Improper use can result in SEVERE INJURY or DEATH ALWAYS USE AN APPROVED HELMET AND PROTECTIVE GEAR FOR DRIVER AND PASSENGER NEVER USE ON PUBLIC ROADS NEVER CARRY MORE THAN 1 PASSENGER NEVER USE WITH DRUGS OR ALCOHOL NEVER operate without proper ATV training or instruction at speeds too fast for your skills or the conditions on public roads a collision can occur with another vehicle with a passenger unless passenger seat is securely in place THE OPERATOR MUST ALWAYS use proper riding techniques to avoid overturns on hills and rough terrain and in turns avoid paved surfaces pavement may seriously affect handling and control reduce speed and use extra caution at all times
26. malfunction See your dealer Electronic throttle control malfunction See your dealer Other mechanical failure See your dealer Overheated engine Clean radiator screen and core clean engine exterior see your dealer Engine Overheating Possible Cause Solution Debris lodged in screen Clean the screen Plugged Radiator Use a garden hose to flush any debris from the radiator fins NOTE High pres sure washers can deform the radiator fins and reduce cooling efficiency 132 POLARIS PRODUCTS Part Number Description Engine Lubricant 2870791 Fogging Oil 12 oz Aerosol 2876244 PS 4 PLUS Performance Synthetic 2W 50 4 Cycle Oil qt 2876245 PS 4 PLUS Performance Synthetic 2W 50 4 Cycle Oil gal Gearcase Transmission Lubricants 2877606 Synthetic Sportsman XP Transmission Fluid qt 95 l 2873602 Premium AGL Synthetic Gearcase Lubricant qt 95 l 2873603 Premium AGL Synthetic Gearcase Lube gal 3 8 I 2877922 Demand Drive Plus Fluid qt 95 1 2877923 Demand Drive Plus Fluid gal 3 8 l 2871653 Premium ATV Angle Drive Fluid 8 0z 237 ml 2872276 Premium ATV Angle Drive Fluid 2 5 gal 9 5 I 2870465 Pump for Gallon 3 8 I Jug Coolant 2871323 60 40 Coolant gal 3 8 I 2871534 60 40 Coolant qt 95 I Grease Specialized Lubricants 2871312 Grease Gun Kit Premium All Season 2871322 Premium All Season Grease 3
27. more time and distance for braking Ride to the ability of your passenger instead of to your own ability Avoid unexpected or aggressive maneuvers that could cause a pas senger to fall from the vehicle OPERATION Driving with a Passenger 12 Do not cross a hillside with a passenger on board See page 64 13 A passenger should alwavs be seated in the passenger seat with both feet on the footrests and both hands on the passen ger grab handles at all times The passenger should never hold on to the operator Never secure a passenger to the vehicle or to the operator with a belt rope or similar device 14 Make sure the passenger understands the importance of active riding When hill climbing or performing maneuvers a passenger should shift body weight in the same manner in which the driver shifts body weight For example the passenger should lean to the inside of a turn along with the operator and should always lean uphill when climbing and descending hills 61 OPERATION Driving on Slipperv Surfaces Sidewavs Turn in skid i direction of skid C IC C D AVA ONE c ET Te eu s Ir C Oc C C S BS CC y Whenever riding on slippery surfaces such as wet trails or loose gravel or during freezing weather follow these precautions 1 Do not operate on excessively rough slippery or loose terrain 2 Slow down when entering slippery areas 3 Engage 4X4 before wheels begin to lose traction
28. of 500 hours of engine operation 5000 kilo meters 3100 miles of vehicle travel or 30 calendar months from the date of purchase whichever comes first This emissions limited warranty covers components whose failure increases the vehi cle s regulated emissions and it covers components of systems whose only purpose is to control emissions Repairing or replacing other components not covered by this war ranty is the responsibility ofthe vehicle owner This emissions limited warranty does not cover components whose failure does not increase the vehicle s regulated emissions For exhaust emissions emission related components include any engine parts related to the following systems Air induction system Ignition system Fuelsystem Exhaust gas recirculation systems The following parts are also considered emission related components for exhaust emis sions Aftertreatment devices Sensors Crankcase ventilation valves Electronic control units The following parts are considered emission related components for evaporative emis sions Fuel Tank Vacuum Control Diaphragms Fuel Cap Control Cables Fuel Line Control Linkages Fuel Line Fittings e Purge Valves Clamps Vapor Hoses Pressure Relief Valves Liquid Vapor Separator Control Valves Carbon Canister Control Solenoids Canister Mounting Brackets Electronic Controls e Carburetor Purge Port Connector As related to the evaporat
29. of the hill 10 Remain alert and be prepared to take emergency action This may include quick dismounting of the vehicle 63 OPERATION Driving on a Sidehill Sidehilling Driving on a sidehill is not recommended Improper procedure could cause loss of control or overturn Avoid crossing the side of any hill unless absolutely necessary If crossing a sidehill is unavoidable follow these precautions 1 Slow down 2 Avoid crossing the side of a steep hill 3 Do notcross a hillside with a passenger on board Ask the passenger to dismount and walk across the hillside before remounting the vehicle 4 Lean into the hill transferring your upper body weight toward the hill while keeping your feet on the footrests 5 Ifthe vehicle begins to tip quickly turn the front wheel downhill if possible or dismount on the uphill side immediately 64 OPERATION Driving Downhill When driving downhill follow these precautions l 2 Always check the terrain carefully before descending a hill Never operate in TURF mode while operating on a hill or other irregular terrain Always move the 4X4 switch to ADC 4X4 before ascending or descending a hill See page 38 Always descend a hill with the transmission in forward gear Do not descend a hill with the transmission in neutral Slow down Never travel down a hill at high speed Drive straight downhill Avoid traveling down a hill at an angle which would cause the
30. side of the ATV Remove the dipstick Wipe it dry with a clean cloth Reinstall and tighten the dipstick Remove the dipstick and check the oil level Add the recommended fluid as needed Maintain the oil level in the safe range between the FULL and ADD marks Do not overfill Reinstall and tighten the dipstick PETS ad A Full Add i3 VM 83 MAINTENANCE Engine Oil Oil and Filter Change See the table on page 81 for fluid recommendations capacities and plug torques Always change the oil and filter at the intervals outlined in the Periodic Maintenance Chart beginning on page 77 Always change the oil filter whenever changing oil Drain q D DI ne to front Filter Access 1 Position the vehicle on a level surface hu Start the engine Allow it to warm up at idle for two to three min utes Stop the engine Clean the area around the drain plug Place a drain pan under the crankcase Dar Rw 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 7 Install a new sealing washer on the drain plug The sealing surfaces on drain plug and crankcase should be clean and free of burrs nicks or scratches 8 Reinstall the drain plug Torque to specification 84 MAINTENANCE Engine Oil Oil and Filter Change 9 10 11 12 13 14 15 16 17
31. sidehill is not recommended Improper procedure could cause loss of control or overturn Avoid crossing the side of any hill unless absolutely necessary If crossing a hillside is unavoidable always follow proper procedures as described in the owner s manual See page 64 Never attempt to turn the ATV around on any gt e SA l d di E hill until you ve mastered the turning technique Js on level ground as described in the owner s gt manual See page 66 Q y S 15 SAFETV Safetv Warnings Stalling While Climbing a Hill Stalling rolling backwards or improperly dismounting while climbing a hill could cause an overturn Always maintain a steady speed when climbing a hill Never operate in TURF mode while operating on a hill or other irregular terrain Always move the 4X4 switch to ADC 4X4 before ascending or descending a hill See page 38 If all forward speed is lost Lean forward to keep body weight uphill A passenger should also lean uphill Apply the single lever brakes Lock the parking brake when fully stopped Dismount on the uphill side of the vehicle or on the left if the vehicle is pointing straight uphill Have a passenger dismount first then the operator may dismount Turn the ATV around and remount following the procedure described in the owner s manual See page 66 If the ATV begins rolling backwards Keep operator and passenger body weight uphill Never appl
32. years Chrome wheels exposed to road salt or salt in the air in coastal areas are more susceptible to corrosion if not properly cleaned Clean chrome wheels more often if they re exposed to salt or other corrosive elements 1 Wash chrome wheels frequently Use a mild detergent Never use abrasive cleaners on plated or painted surfaces 2 Rinse well with clear water Soap detergents salt dirt mud and other elements can cause corrosion 3 Polish the clean chrome wheels periodically Use an automotive grade chrome polish 4 Routinely and liberally apply a weather resistant wax to each pol ished chrome wheel Choose a product suitable for chrome finishes Read and follow the product labels and instructions Removing Corrosion If light rust is found on the chrome finish use steel wool 0000 OTT grade to remove it Gently rub the affected areas with the steel wool until the corrosion has been removed Clean and polish the wheel as out lined above 125 MAINTENANCE Cleaning and Storage Storage Tips NOTICE Starting the engine during the storage period will disturb the protective film created bv fogging and damage could occur Never start the engine during the storage period Clean the Exterior Make anv necessarv repairs and clean the vehicle as recommended See page 123 Stabilize the Fuel 1 Fillthe fuel tank 2 Add Polaris Carbon Clean Fuel Treatment or Polaris Fuel Stabilizer Follow the instructions on th
33. 009 2010 76 8 O VAM RZR 170 2009 2010 813 PB20 __ PHOENIX 200 2008 2009 2010 76 8 BA32 TRAIL BLAZER 330 2008 2009 2010 76 8 CA3 TRAIL BOSS 330 2008 2009 2010 76 8 BAS0 SCRAMBLER 500 2008 2009 2010 79 6 GM5 OUTLAW 450 2008 2009 2010 80 7 GJS2 GP52 OUTLAW 525 2008 2009 2010 80 7 OLH27 SPORTSMAN 300 2008 2009 2010 81 1 LH46 SPORTSMAN 400 2008 2009 2010 802 MN50 SPORTSMAN 500 EFI 2008 2009 2010 804 ZN55 ZX55 SPORTSMAN 550 EFI 2009 2010 80 8 TN55 _DNSS SPORTSMAN X2 TOURING 550 2010 712 MN 76 SPORTSMAN 800 2008 2009 2010 83 6 TN85 DN85 SPORTSMAN X2 TOURING 850 2010 712 CLI6 SPORTSMAN 800 6X6 2009 2010 80 1 ZN85 ZX85 SPORTSMAN 850 EFI 2009 2010 80 4 RH50 HH50 RANGER 500 EFI 4X4 2009 2010 76 5 HH76 RANGER 800 EFI 4X4 2010 76 5 WH76 RANGER 800 EFI CREW 2010 76 5 HR RANGER 800 6X6 2010 76 5 HY _ RANGER HD 800 4X4 2010 76 5 VH76 RANGER RZR 2008 2009 2010 85 8 Authorized Signatory Vr A T 4 Pamata Alexander A Kennedy Product Compliance Polaris Industries Inc Engineering Operations 301 5th Avenue SW Roseau MN 56751 136 WARRANTV LIMITED WARRANTV Polaris Sales Inc 2100 Highway 55 Medina MN 55340 gives a SIX MONTH LIM ITED WARRANTY on all components of the Polaris All Terrain Vehicle ATV against defects in material or workmanship Polaris also gives a one year limited warranty on the fin
34. 57 Consumer Product Safety 7 Coolant Bottle 93 Coolant Radiator 94 Cooling System 92 94 Corrosion Removal Chrome 125 Crankcase Emission Control System 76 148 D Demand Drive Fluid 87 Diagnostic Codes 51 Disengaging Active Descent Control 38 Display Standard Metric 47 Drive Belt Wear Burn 129 Drivetrain Break In 53 Driving Downhill 65 Driving in Reverse 70 Driving on a Sidehill 64 Driving on Slippery Surfaces 62 Driving Over Obstacles 69 Driving Procedures 58 Driving Through Water 68 Driving Uphill o e aauuaaaaa 63 Driving with a Passenger 60 61 E Electromagnetic Interference 76 Emissions Limited Warranty 143 144 Engaging 4X4 00 2 eee 37 Engaging Active Descent Control 38 Engine Break In 53 Engine Fogging 127 Engine Oil 82 85 Engine Stop Switch 28 EPS Warning Indicator 45 Equipment Modifications 9 Etiquette Trail Riding 56 Exhaust Emission Control System 76 Eye Protection 9 F Fluid ADO e cien SIS 90 91 Biaken e eben S 32 Demand Drive 87 Engine Oil 83 Rear Gearcase 88 Transmission Oil 86 Fluid Change PD op E 91 Demand Drive
35. 66 67 Turning the Vehicle 59 INDEX V Vehicle Identification Numbers 6 Vehicle Immersion 108 MIN Seti Dosa tte Is SIRVA 6 Ww Warning Symbols 4 Washing the Vehicle 123 124 Wheel Installation 99 Wheel Nut Torque Specifications 99 Wheel Removal 98 151
36. ANCE Spark Plugs Spark Plug Inspection Normal Spark Plug The normal insulator tip is grav tan or light brown There will be few combustion deposits The electrodes are not burned or eroded This indi cates the proper tvpe and heat range for the engine and the service The tip should not be flakv and white A white insulator tip indicates overheating caused by use of an improper spark plug or incorrect fuel Wet Fouled Spark Plug The wet fouled insulator tip is black A damp oil film covers the firing end There may be a carbon layer over the entire nose Generally the electrodes are not worn General causes of fouling are excessive oil use of non recommended oil or incorrect throttle body adjustments 107 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 plugs Dry the spark plugs Reinstall the plugs or install new plugs Attempt to start the engine If necessary repeat the drying proce dure 3 4 Turnthe engine over several times using the electric start 5 6 7 Take th
37. Adjustment 104 Lower Headlamp Replacement 105 Taillight Brakelight 105 Low Beam Adjustment 104 Low Range Use 111 Lower Headlamp Replacement 105 Lubrication Guide 81 M Maintenance Chart 77 80 Master Cylinder 32 Metric Standard Display 47 Mode Switch 000 28 Modifications 0 9 N Noise Emission Control Svstem 76 Oo Oil Engine 82 85 Rear Gearcase 88 89 Transmission 86 Oil Change Engine Oil and Filter 84 85 Rear Gearcase 89 Transmission 86 Oil Level Engin 25 das Jo s daha ages 83 Rear Gearcase 88 Transmission 86 Oil Recommendations 82 Operation on Public Lands 76 Override Switch 0 28 149 INDEX P Parking Brake 33 Parking on an Incline 71 Passenger Seat 40 41 Periodic Maintenance Chart 77 80 Polaris Product List 133 Polishing the Vehicle 124 Pre Ride Checklist 54 PVT Break In 0 00000 53 PVT Drying uber RIS 111 PVT Svstem 110 111 R Rack Compartment Front 42 Reverse Operation 70 Reverse Override Switch 28 Rider Information Center 44 51 Riding Area 000000 ee 56 Riding Gear 8 9 S Safe Operation Practices 55
38. ECT button to advance the hours After the hours are set press and release the MODE button to move to the minutes Use the same procedure to reset the minutes 5 When the digits stop flashing the clock has been set Method 2 1 With the key turned off press and hold the MODE button 2 While still holding the MODE button turn the key to the ON posi tion 3 Continue to hold the MODE button until the hour display flashes Release the button 4 Setthe time as outlined in steps 3 5 of Method 1 48 FEATURES AND CONTROLS Instrument Cluster Rider Information Center Information Displav Area Diagnostic Displav Mode The EFI diagnostic display mode is for informational purposes only Please see your Polaris dealer for all major repairs The diagnostic mode is accessible only when the check engine warning indicator activates after the key has been turned on Leave the key on if you want to view the active code failure code The diagnostic mode becomes inaccessible if the key is turned off and on and the warning indicator is no longer active This allows the deter mination of persistent as well as intermittent faults Inactive codes are stored in the history of the unit Please see your Polaris dealer to retrieve inactive codes Use the following procedure to view active codes that occur when the key is on 1 Place the transmission in PARK 2 Press and release the SELECT button until the flashing check engine warn
39. Excessive throttle operation while in the speed limit mode may cause 70 fuel to build in the exhaust resulting in engine popping and or engine damage OPERATION Parking on an Incline Avoid parking on an incline if possible If it s unavoidable follow these precautions 1 2 3 4 Stop the engine Place the transmission in PARK Lock the parking brake Always block the rear wheels on the downhill side 71 OPERATION Hauling Cargo A WARNING Overloading the vehicle or carrying or towing cargo improperly can alter vehicle handling and may cause loss of control or brake instability Always follow these precautions when hauling cargo Never carry cargo in the rear box when operating the ATV in the 2 up mode with a passenger REDUCE SPEED AND ALLOW GREATER DISTANCES FOR BRAKING WHEN HAULING CARGO NEVER EXCEED THE MAXIMUM WEIGHT CAPACITY of the vehicle When determining the weight you are adding to the vehicle include the weight of the operator passenger accessories loads in the rack or box and the load on the trailer tongue The combined weight of these items must not exceed the maximum weight capacity REDUCE SPEED AND CARGO to maintain stable driving conditions when operating over rough or hilly terrain WEIGHT DISTRIBUTION in the cargo bed should be as far forward and as low as possible Carrying a high load raises the center of gravity and creates a less stable operating condition Reduce load weight
40. Filters Batteries unless defective Fuel Cosmetic damage repair Sealants Coolants Hotel fees Meals Towing charges Shipping handling fees Mileage Product pick up delivery Rentals Loss of product use Loss of vacation personal time 138 WARRANTV LIMITATIONS OF WARRANTIES AND REMEDIES This warrantv also excludes failures resulting from improper lubrication improper engine timing improper fuel surface imperfections caused bv external stress heat cold or contamination operator error or abuse improper component alignment tension adjustment or altitude compensation failure due to snow water dirt or other foreign substance ingestion contamination improper maintenance modified components use of aftermarket components resulting in failure unauthorized repairs repairs made after the warrantv period expires or bv an unauthorized repair center use of the product in competition or for commercial purposes Warranty will not apply to any product which has been damaged by abuse accident fire or any other casualty not determined a defect of materials or workmanship This warranty does not cover the use of unauthorized lubricants chemicals or fuels that are not compatible with the ATV The exclusive remedy for breach of this warranty shall be at Polaris exclusive option repair or replacement of any defective materials or com ponents or products THE REMEDIES SET FORTH IN THIS WARRANTY ARE THE ONLY REMEDIE
41. Overall Height 49 5 in 125 7 cm Wheelbase 57 in 145 cm Ground Clearance 11 25 in 28 6 cm Minimum Turning Radius 96 in 244 cm unloaded 82 in 208 cm in TURF mode Engine ESSSOPLE Displacement 549 7 cc Bore x Stroke 96 6 x 75 Alternator Output 490w 1350 RPM Peak 630w Compression Ratio 9 6 1 Starting System Electric Ignition System Electronic Fuel Injection Idle RPM 1750 50 Ignition Timing 13 3 BTDC 1350 RPM Engine warm Spark Plug Gap NGK BKRG6E 035 in 0 9 mm Lubrication System Wet Sump Driving System Type Automatic PVT Polaris Variable Transmission Front Suspension Dual A Arm with 9 22 9 cm travel Rear Suspension Progressive rate with 10 25 4 cm travel Based on EU Directive 76 432 EC A higher initial idle speed of 1800 RPM will occur for the first few minutes of operation 134 SPECIFICATIONS Sportsman X2 550 EFI Transmission H L N R P Gear Reduction Low 5 034 1 Gear Reduction Reverse 4 508 1 Gear Reduction High 2 693 1 Drive Ratio Front 3 818 1 Tires Pressure Front 26x8 14 AT 7 psi 48 3 kPa Tires Pressure Rear 26x10 14 AT 5 psi 34 5 kPa Brakes Front Rear Single Control Hydraulic Disc All Wheel Brake Auxiliary Foot Activated Hydraulic Disc Rear Wheel Brake Parking Hydraulic lock all wheel
42. S AVAILABLE TO ANY PERSON FOR BREACH OF THIS WAR RANTY POLARIS SHALL HAVE NO LIABILITY TO ANY PERSON FOR INCI DENTAL CONSEQUENTIAL OR SPECIAL DAMAGES OF ANY DESCRIPTION WHETHER ARISING OUT OF EXPRESS OR IMPLIED WARRANTY OR ANY OTHER CONTRACT NEGLIGENCE OR OTHER TORT OR OTHERWISE Some states do not permit the exclusion or limitation of incidental or consequential damages or implied warranties so the above limitations or exclusions may not apply to you if inconsistent with controlling state law 139 WARRANTV ALL IMPLIED WARRANTIES INCLUDING BUT NOT LIMITED TO THE IMPLIED WARRANTIES OF MERCHANTABILITV AND FITNESS FOR A PAR TICULAR PURPOSE ARE LIMITED IN DURATION TO THE ABOVE SIX MONTH WARRANTV PERIOD POLARIS FURTHER DISCLAIMS ALL EXPRESS WARRANTIES NOT STATED IN THIS WARRANTV Some states do not allow limi tations on how long an implied warrantv lasts so the above limitation mav not applv to you if inconsistent with controlling state law HOW TO OBTAIN WARRANTY SERVICE If your ATV requires warranty service you must take it to a Polaris dealer authorized to repair Polaris ATVs When requesting warranty service you must present your copy of the Warranty Registration form to the dealer THE COST OF TRANSPORTATION TO AND FROM THE DEALER IS YOUR RESPONSIBILITY Polaris suggests that you use your original selling dealer however you may use any Polaris Servicing Dealer to perform warranty service Please work with your dealer to
43. The handlebars can be adjusted for rider preference WARNING Improper adjustment of the handlebars or incorrect torquing of the adjuster block tightening bolts can cause limited steering or loosening of the handlebars resulting in loss of control and serious injury or death Follow the adjustment procedures exactly or see your Polaris dealer for service 1 Remove the upper headlight pod 2 Loosen the four handlebar bolts 3 Adjust the handlebar to the desired height Be sure the handlebars do not contact the gas tank or any other part of the machine when turned fully to the left or right Handlebar 4 Torque the front two bolts to Bolts 10 12 ft Ibs 14 17 Nm then torque the rear two bolts A gap of up to 1 8 3 mm will remain at the rear of the clamp blocks 120 MAINTENANCE Camber and Caster The camber and caster are non adjustable Front and Rear Springs The front and rear shock absorber springs are adjusted bv rotating the adjuster either clockwise or counter clockwise to increase or decrease spring tension Accessory springs are available through your Polaris dealer 121 MAINTENANCE Transporting the ATV Follow these procedures when transporting the vehicle 1 Stop the engine 2 Place the transmission in PARK 3 Lock the parking brake 4 Always secure the seat in the l up position to prevent loss during transporting Secure the fuel cap and oil cap 6 Always tie the frame
44. ake fluid Brake fluid will damage rubber components in the hydraulic system 1 Remove the front rack ADC Fluid 2 View the fluid level in the Reservoir reservoir 3 Ifthe level is below the minimum mark remove the cap and add the recommended fluid Reinstall the cap 5 Reinstall the front rack 90 MAINTENANCE Active Descent Control ADC Fluid Fluid Change 1 Position the vehicle on a level surface Before performing the Rd fluid change allow the vehicle Cap to sit for at least 30 minutes Bleeder Thoroughly clean the areas Valve around and on the ADC reservoir and bleeder valves one on each side of the differential Remove the reservoir cap and diaphragm assembly Use a shop towel or suction tool to remove debris from the fluid and reservoir Debris in the reservoir may result in inadequate bleeding and reduced performance of the system Fill the reservoir to the maximum line with fresh ADC fluid Remove the protective caps from the bleeder valves Slowly loosen one of the screws turn counter clockwise and allow fluid and trapped air to flow from the fitting Tighten the screw when clean fluid begins to flow Repeat this step for the remaining valve IMPORTANT Close the bleeder valves before the reservoir fluid level drops below the minimum fill line Adding fluid to an empty reservoir will result in trapped air If the level drops below the minimum line add fluid to the maximu
45. al drive chain for failure due to defects This warranty covers the parts and labor charges for repair or replacement of defective parts which are covered by this warranty This warranty begins on the date of purchase This warranty is transferable to another consumer during the warranty period through a Polaris dealer REGISTRATION At the time of sale the Warranty Registration Form must be completed by your dealer and submitted to Polaris within ten days Upon receipt of this registration Polaris will record the registration for warranty No verification of registration will be sent to the purchaser as the copy of the Warranty Registration Form will be the warranty entitle ment If you have not signed the original registration and received the customer copy please contact your dealer immediately NO WARRANTY COVERAGE WILL BE ALLOWED UNLESS YOUR ATV IS REGISTERED WITH POLARIS Initial dealer preparation and set up of your ATV is very important in ensuring trouble free operation Purchasing a machine in the crate or without proper dealer set up will void your warranty coverage 137 WARRANTV WARRANTY COVERAGE AND EXCLUSIONS LIMITATIONS OF WARRANTIES AND REMEDIES The Polaris limited warranty excludes any failures that are not caused by a defect in material or workmanship This warranty does not cover accidental damage normal wear and tear abuse or improper handling This warranty also does not cover any ATV that has been altered struct
46. and use extra caution at all times when carrying a passenger dismount passenger when conditions require e make sure passenger reads and understands this label and passenger safety label READ OWNER S MANUAL FOLLOW ALL INSTRUCTIONS AND WARNINGS For your nearest Polaris dealer PELARIS callt 800 POLARIS The Way Out or visit www polarisindustries com Polaris Sales Inc 2100 Hwy 55 Medina MN 55340 Phone 1 888 704 5290 Part No 9922051 Rev 03 Printed in USA WELCOME Thank vou for purchasing a Polaris vehicle and welcome to our world wide family of Polaris owners We proudly produce an exciting line of utility and recreational products Snowmobiles All terrain vehicles ATVs RANGER utility vehicles Victory motorcycles We believe Polaris sets a standard of excellence for all utility and recre ational vehicles manufactured in the world today Many years of experi ence have gone into the engineering design and development of your Polaris vehicle making it the finest machine we ve ever produced For safe and enjoyable operation of your vehicle be sure to follow the instructions and recommendations in this owner s manual Your manual contains instructions for minor maintenance but information about major repairs is outlined in the Polaris Service Manual and should be performed only by a factory certified Master Service Dealer MSD technician Your Polaris dealer knows your vehicle best and is interested i
47. ank or fuel lines See your dealer Slippage from failure to warm up belt Always warm up the belt by operating below 30 mph for one mile 5 miles or more when temperature is below freezing Wrong or missing belt Install the recommended belt Improper break in Always break in a new belt and or clutch See page 53 129 TROUBLESHOOTING Engine Doesn t Turn Over Possible Cause Low batterv voltage Solution Recharge the batterv to 12 8 VDC Loose batterv connections Check all connections and tighten Loose solenoid connections Check all connections and tighten Engine Turns Over Fails to Start Possible Cause Out of fuel Solution Refuel cvele kev to ON position three times for 5 seconds each then start Clogged fuel filter See vour dealer Water is present in fuel Drain the fuel svstem and refuel Old or non recommended fuel Replace with fresh recommended fuel Fouled or defective spark plug s 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 plug s Incorrect spark plug gap or hea
48. any cargo from the cargo box before removing the seat 2 Standon the right side of the vehicle Pull the cargo box release lever upward Lift the front of the cargo box 3 Grasp edge of the seat near the left rear corner 4 Pull upward abruptly to disen E ee c UN AQ gage the under seat fasteners fa 5 Remove the seat Side Panel Footwell Removal Remove the seat before removing a side panel Remove the fasteners securing the side panel or footwell to remove it Screw QS Plastic Rivet Plastic Rivet Hex Head Screw 97 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 134 for recom mended tire type size and pressure Tire Tread Depth Always replace tires 1 8 3 mm Y when tread depth is worn to 1 8 3 mm or less ep ISS Front Wheel Hub Tightening Front wheel bearing tightness and spindle nut retention are critical com ponent operations All service must be pe
49. as needed to bring the level to the bottom of the fill hole threads Do not overfill 4 Reinstall the fill plug Torque to specification 88 MAINTENANCE Rear Gearcase Oil Oil Change 1 Position the vehicle on a level surface 2 Place a drain pan under the drain hole 3 Remove the drain plug Allow the oil to drain completely 4 Clean and reinstall the drain plug with a new sealing washer Torque to specification 5 Remove the fill plug Add the proper amount of the recommended oil Do not overfill 6 Reinstall the fill plug Torque to specification Check for leaks 8 Dispose of used oil properly 89 MAINTENANCE Active Descent Control ADC Fluid Fluid Level If vour vehicle is equipped with Active Descent Control there are two fluid levels that must be maintained demand drive fluid and ADC fluid See page 87 for demand drive fluid maintenance Check and change the ADC fluid level at the intervals outlined in the Periodic Maintenance Chart beginning on page 77 NOTICE Change the ADC fluid everv 25 hours if the ADC unit is exposed to extreme use Extreme use includes operation in ADC mode for prolonged periods or in environments that necessitate primarv operation in ADC mode We recommend the use of Polaris Demand Drive Plus Fluid for the ADC unit Maintain the fluid level between the minimum and maximum marks on the reservoir See page 133 for the part numbers of Polaris products NOTICE Do not use br
50. bs 11ft lbs Page 87 Fluid Front Plus Fluid 275 ml 11 14 Nm 15 Nm Gearcase Rear ATV Angle Drive 6 1 0z 10 14 ft Ibs 10 14 ft Ibs Page 88 Gearcase Oil Fluid or GL5 80 180 ml 14 19 Nm 14 19 Nm 90 weight gear lube Brake Fluid DOT 4 Only Page 32 ADC Fluid Demand Drive Page 90 Plus Fluid Front Prop Polaris Premium Grease fittings 3 pumps maximum every 500 miles Shaft Yoke U Joint Lube before long periods of storage or after pressure washing or submerging f Front Prop Shaft Yoke 81 MAINTENANCE Engine Oil Oil Recommendations Polaris recommends the use of Polaris PS 4 PLUS Performance Syn thetic 2W 50 4 cycle oil or a similar oil for this engine See the table on page 81 for fluid recommendations capacities and plug torques Oil may need to be changed more frequently if Polaris oil is not used Always use 2W 50 oil Follow the manufacturer s recommendations for ambient temperature operation See page 133 for the part numbers of Polaris products NOTICE Mixing brands or using a non recommended oil may cause serious engine damage Always use the recommended oil Never substitute or mix oil brands 82 MAINTENANCE Engine Oil Oil Level Check the oil level when the engine is cold Never check the oil with the engine running l 2 3 Position the vehicle on a level surface Access the oil dipstick and fill tube from the left
51. ch trip if reset before each trip To reset a trip meter select the trip meter 1 or trip meter 2 mode Press and hold the MODE button on the instrument clus ter until the total changes to 0 In the Rider Information Center the trip meter display contains a decimal point but the odometer displays with out a decimal point Hour Meter Mode This mode logs the total hours the engine has been in operation 47 FEATURES AND CONTROLS Instrument Cluster Rider Information Center Information Displav Area Programmable Service Interval When the hours of engine operation equal the programmed service interval setting the wrench icon will flash for 5 seconds each time the engine is started When this feature is enabled it provides a convenient reminder to perform routine maintenance The service interval is pro grammed at 50 hours at the factorv Use the following procedure to change the service interval 1 Press the SELECT button until remaining service hours display 2 Press and hold the MODE button 3 When the service hours flash press and release the SELECT button to advance the hours to the desired setting including OFF When the digits stop flashing the interval has been set Clock Mode Use one of the following two methods to reset the clock Method 1 1 Select the Hour Meter Mode 2 Press and hold the mode button on the instrument cluster until the hour display flashes Release the button 3 Press and release the SEL
52. cle speed exceeds 15 mph 24 km h The throttle is open throttle is applied The transmission is shifted to neutral or park 38 FEATURES AND CONTROLS Fuel Tank Cap Remove the fuel tank cap to add fuel to the fuel tank Use either leaded or unleaded gasoline with a minimum pump octane number of 87 R M 2 octane Do not use fuel with ethanol content greater than 10 percent such as E 85 fuel Alwavs refuel with the engine stopped and outdoors or in a well ventilated area Refuel on a level sur face The fuel tank is designed to allow for the normal expansion of fuel Do not Fuel Tank overfill Do not fill the tank neck Cap 39 FEATURES AND CONTROLS Passenger Seat Always make sure the passenger seat lock out is functioning properly before operating with a passenger Do not operate the vehicle with the seat in the 2 up position when oper ating without a passenger Always return the seat to the 1 up position for single rider operation Never carry cargo in the rear box when operating the ATV in the 2 up mode with a passenger Seat Conversion 1 Make sure the cargo box dump lever is securely latched 2 Rotate both operator backrest latches 1 4 turn to release the locks 3 Tilt the backrest slightly forward 4 Pull the passenger backrest upward from the bed of the cargo box Operator Backrest Latches view from front Locked Unlocked Passenger Dump Lever Backrest
53. corrosion or defects caused by fire explosions or other similar causes beyond the control of Polaris Owners are responsible for performing the scheduled maintenance identified in the owner s manual Polaris may deny warranty claims for failures that have been caused by the owner s or operator s improper maintenance or use by accidents for which Polaris has no responsibility or by acts of God Any qualified repair shop or person may maintain replace or repair the emission con trol devices or systems on your vehicle Polaris recommends that you contact an autho rized Polaris dealer to perform any service that may be necessary for your vehicle Polaris also recommends that you use only Pure Polaris parts It is a potential violation of the Clean Air Act if a part supplied by an aftermarket parts manufacturer reduces the effectiveness of the vehicle s emission controls Tampering with emission controls is prohibited by federal law If you have any questions regarding your warranty rights and responsibilities please contact the Polaris Warranty Department at 1 888 704 5290 144 MAINTENANCE LOG Present this section of your manual to your dealer each time your vehicle is serviced This will provide you and future owners with an accurate log of maintenance and ser vices performed DATE MILES KM OR HOURS TECHNICIAN SERVICE PERFORMED COMMENTS 145 MAINTENANCE LOG
54. d on the D Fill bottom right side of the Level unit Fluid Check 1 Position the vehicle on a level surface Remove the fill plug Check the fluid level E 2 Add the recom 9 mended fluid as needed to bring the level to the bottom of the fill hole threads 3 Reinstall the fill plug Torque to specification Fluid Change 1 Position the vehicle on a level surface Remove the fill plug Va Drain Plug 2 Place a drain pan under the demand drive unit Remove the drain plug Allow the fluid to drain completely Clean and reinstall the drain plug Torque to specification Add the proper amount of the recommended fluid Reinstall the fill plug Torque to specification QUEE rd Check for leaks Dispose of used fluid properly 87 MAINTENANCE Rear Gearcase Oil See the table on page 81 for fluid recommendations capacities and plug torques Always check and change the rear gearcase oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 77 See page 133 for the part numbers of Polaris products The fill plug is located on the rear of the gearcase The drain plug is located on the bottom of the gearcase Fill Maintain the fluid level at the Level bottom of the fill hole threads Do not overfill Oil Check 1 Position the vehicle on a m f level surface Or 2 Remove the fill plug Fill Plug Check the oil level Drain Plug 3 Add the recommended oil
55. d plant feet firmly on footrests while seated in the passenger seat tell operator to slow down or stop if uncomfortable get off and walk if conditions require WARNING Never operate this ATV on HILLS steeper than 15 degrees 15 To prevent overturn on hilly terrain use throttle and brakes gradually and shift weight uphill REVERSE operation can be dangerous even at low speeds Steering becomes difficult To prevent loss of control avoid sudden braking or sharp turns 7175845 24 SAFETV Safetv Labels and Locations Tire Pressure Load Warning WARNING Tire Pressure Load Improper tire pressure or overloading Warning can cause loss of control Loss of control can result in severe injurv or death Cold tire pressure Front 7 0 psi 48 3 kPa Rear 5 0 psi 34 5 kPa Maximum weight capacity 735 Ibs 333 kg Lug nut torque values Steel rims 45 ft Ibs 61 Nm Aluminum rims 75 ft lbs 102 Nm 7175846 25 SAFETV Safetv Labels and Locations Box Rack Warning Warning Clutch Cover Warning under seat Rack Warning Front WARNING DO NOT TOW FROM RACK OR BUMPER Vehicle damage or tipover mav result causing severe injury or death Tow only from tow hooks or hitch Maximum combined Front Rack and Container Load 120 Ibs 54 kg 7175847 Clutch Cover Warning WARNING NO STEP Moving parts hazard under belt clutch guard To prevent serious injury do n
56. dards A passenger on approved models should wear a hel met that includes a rigid chin guard Approved helmets in the USA and Canada bear a U S Department of Transportation DOT label Approved helmets in Europe Asia and Oceania bear the ECE 22 05 label The ECE mark consists ofa 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 SAFETV Safe Riding Gear Eve Protection Do not depend on eveglasses or sunglasses for eve protection When ever riding a Polaris vehicle alwavs wear shatterproof goggles or use a shatterproof helmet face shield Polaris recommends wearing approved Personal Protective Equipment PPE bearing markings such as VESC 8 V 8 Z87 1 or CE Make sure protective eve wear is kept clean Gloves Off road style gloves with knuckle pads are the best for comfort and protection Boots The best footwear 1s 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
57. de of each spark plug cap and rein stall the caps onto the plugs 5 Turn the engine over several times Oil will be forced in and around the piston rings and ring lands coating the cylinder with a protec tive film of fresh oil 6 IfPolaris fuel system additive is not used the fuel tank fuel lines and injectors should be completely drained of gasoline 127 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 77 Batterv Storage See pages 115 116 for storage and charging procedures Storage Area Covers Set the tire pressure and safely support the ATV with the tires slightly off the ground Be sure the storage area is well ventilated Cover the vehicle with a genuine Polaris cover Do not use plastic or coated mate rials They do not allow enough ventilation to prevent condensation and may promote corrosion and oxidation Accessories Auxiliary power outlets provide 12 volt power for operating accesso ries Accessory outlets are available for all models Polaris also has a wide range of additional accessories available for your ATV Always install accessories that are approved for ATV use Please see your Polaris dealer 128 TROUBLESHOOTING Drive Belt Wear Burn Possible Cause Driving onto a pickup or tall trailer in high range Solution Use low range during loading
58. der 12 years of age to ride as a passenger on this 2 up ATV Even though a child may be within the recommended age group for operating some ATVs he she may not have the skills abilities or judgment needed to operate or ride on this ATV safely and could be susceptible to accident or injury 10 SAFETV Safetv Warnings Handling Gasoline Gasoline is highly flammable and explosive under certain conditions Always exercise extreme caution whenever handling gasoline Always refuel with the engine stopped and outdoors or in a well ventilated area Do not smoke or allow open flames or sparks in or near the area where refueling is performed or where gasoline is stored Do not overfill the tank Do not fill the tank neck If gasoline spills on your skin or clothing immediately wash it off with soap and water and change clothing Exposure to Exhaust Engine exhaust fumes are poisonous and can cause loss of consciousness or death in a short time Never start the engine or let it run in an enclosed area The engine exhaust from this product contains chemicals known to cause cancer birth defects or other reproductive harm Operate this vehicle only outdoors or in well ventilated areas Failure to Inspect Before Operating Failure to inspect and verify that the ATV is in safe operating condition before operating increases the risk of an accident Always inspect the ATV before each use to make sure it s in safe operating condi
59. dverselv affect the handling of the ATV and could result in loss of control and accident or overturn Avoid operating the ATV on pavement ATV tires are designed for off road use If it s unavoidable travel slowly and avoid sudden turns or stops Operating on Public Roads Operating this ATV on public streets roads or highways could result in a collision with another vehicle Never operate the ATV on any public street road or highway including dirt and gravel roads In many states it s unlawful to operate ATVs on public streets roads and highways Operating at Excessive Speeds Operating the ATV at excessive speeds increases the operator s risk of losing control Never operate at excessive speeds Travel at speeds appropriate for your skills your passenger s skills and operating conditions 13 SAFETV Safetv Warnings Physical Control of the ATV Removing even one hand or foot can reduce abilitv to control the vehicle or could cause loss of balance and ejection from the ATV If a person s feet are not firmly planted on the footrests they could come into contact with the wheels or other moving parts and lead to accident or injury Always keep both hands on the handlebars and both feet on the footrests of the ATV during operation A passenger should always be seated in the passenger seat with both feet on the footrests and both hands on the passenger grab handles at all times The passenger should never
60. e 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 111 for drying out the PVT 108 MAINTENANCE Spark Arrestor A WARNING Failure to heed the following warnings while servicing the spark arrestor could result in serious injury or death Never run the engine in an enclosed area Remove any combustible materials from the area Wear eye protection and leather work gloves Do not stand behind or in front of the vehicle while purging Never go under the vehicle while it s inclined The exhaust system can get extremely hot Do not perform service on the spark arrestor while the system is hot Allow components to cool sufficiently before proceeding Use the following procedure to periodically purge accumulated carbon from the exhaust pipe muffler 1 Remove the arrestor clean out plug from the bottom of the muffler 2 Place the transmission in PARK 3 Start the engine ERE 4 Quickly squeeze and SEA Ill release the throttle lever several times to purge car bon from the system Clead Out 5 Ifcarbon comes out of the Plug exhaust cover or plug the exhaust outlet s Wear protective gloves 6 Lightly tap on the exhaust pipe with a rubber mallet while repeating step 4 7 Ifparticles are still suspected to be in the muffler elevate the rear of the vehicle one foot 30 cm hi
61. e 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 84 Air Filter Air Box 1 Inspect and clean or replace the pre cleaner and air filter See page 100 2 Clean the air box 126 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 77 Demand drive unit front gearcase ADC fluid ADC models change every two years Rear gearcase 1f equipped Transmission Brake fluid change every two years and any time the fluid looks dark or contaminated Coolant test strength fill Fog the Engine 1 Treat the fuel system with Polaris Carbon Clean Follow the instruc tions on the container Start the engine Allow it to idle for several minutes so the Carbon Clean reaches the injectors Stop the engine 2 Remove the spark plugs and add 2 3 tablespoons of engine oil To access the plug holes use a section of clear 1 4 hose and a small plastic squeeze bottle filled with the pre measured amount of oil 3 Reinstall the spark plugs Torque to specification 4 Apply dielectric grease to the insi
62. e oil and the filter at 20 hours one month or 500 miles 800 km whichever comes first PVT Break in Clutches Belt A proper break in of the clutches and drive belt will ensure a longer life and better performance Break in the clutches and belt by operating at slower speeds during the break in period as recommended Pull only light loads Avoid aggressive acceleration and high speed operation dur ing the break in period 53 OPERATION Pre Ride Checklist Failure to inspect and verifv that the ATV is in safe operating condition before operating increases the risk of an accident Alwavs inspect the ATV before each use to make sure it s in safe operating condition Item Remarks Page Passenger seat lock out Ensure proper operation 40 Brake system lever travel Ensure proper operation al Brake fluid Ensure proper level 32 Auxiliary brake Ensure proper operation 34 Front suspension Inspect lubricate if necessary 81 Rear suspension Inspect lubricate if necessary 81 Steering Ensure free operation Tires Inspect condition and pressure 98 Wheels fasteners Inspect ensure fastener tightness a Frame nuts bolts fasteners Inspect ensure tightness Fuel and oil Ensure proper levels 33 Coolant level Ensure proper level a Coolant hoses Inspect for leaks Throttle Ensure proper operation v Indicator lights switches Ensure operation 28 Engine stop switch Ensure p
63. e protection required in your area 92 MAINTENANCE Cooling Svstem Recoverv Bottle Coolant The recoverv bottle fluid level can be viewed from inside the front right wheel well Access the recoverv bottle cap under the front storage com partment 1 View the fluid level in the bottle 2 Ifthelevelis low remove the front rack 3 Remove the bottle cap and add coolant as needed Maintain the coolant level between the minimum and maximum marks on the bottle when the fluid is cool 4 Reinstall the cap 5 Reinstall the front rack Recovery Bottle Cap 93 MAINTENANCE Cooling Svstem Radiator Coolant To ensure that the coolant maintains its abilitv to protect the engine Polaris recommends that vou drain the svstem completelv everv two years and add a fresh mixture of antifreeze and water Replace the coolant any time the cooling system has been drained for maintenance or repair If the recovery bottle has run dry check the level in the radiator Add coolant as needed CAUTION Escaping steam can cause burns Never remove the pressure cap while the engine is warm or hot Always allow the engine to cool before removing the pressure cap 1 Remove the front rack 2 Remove the pressure cap 3 Using a funnel slowly add coolant through the radiator filler neck 4 Reinstall the pressure cap Use ofa non standard pressure cap will not allow the recovery system to func tion properly Contact your dealer f
64. e rack as shown in the illustration Position the front edge in the tabs then push the rack downward and secure the latches Access the following compo nents in the front compart ment Radiator cap Brake fluid reservoir ADC fluid reservoir Coolant recovery bottle cap Electrical fuse relay components Brake Fluid Reservoir Electrical Fuse Relay Coolant Bottle Cap Radiator ADC Fluid Cap Reservoir 42 FEATURES AND CONTROLS Instrument Cluster Your ATV is equipped with an instrument cluster that senses vehicle speed from a gear in the transmission The instrument cluster measures distance in miles kilometers as well as hours of operation In addition to showing vehicle speed the instrument cluster also dis plays the following items engine speed odometer resettable trip meters 2 total engine hours of operation service interval timer and indicator gear position fuel level AWD status EPS status if equipped high beam status battery voltage warning temperature warning and diagnos tic display mode These features are outlined on the following pages Directional BEA sis Indicator Rider Information Center EPS Warning Indicator if equipped Neutral Over Temperature Indicator Indicator 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 re
65. ear wheels allowing the turn to be made smoothly The same leaning technique should be used for turning in reverse 6 Practice making turns at slow speeds before attempting to turn at faster speeds WARNING Turning improperly can result in vehicle overturn Never turn abruptly or at sharp angles Never turn at high speeds 59 OPERATION Driving with a Passenger 1 10 11 60 Never allow anyone under 12 years of age to ride as a passenger on this 2 up ATV Make sure any passenger is tall enough to comfort ably and safely reach the grab handles and footrests Do not carry a passenger until you have at least two hours of driving experience with this vehicle Make sure the passenger is wearing appropriate riding gear includ ing an approved helmet with a rigid chin guard See page 8 Perform the pre ride inspection See page 54 Convert the seat for 2 up riding See page 40 Always make sure the passenger seat lock out is functioning properly before carrying a passenger Lock the parking brake Mount the vehicle from the left side After the operator is seated the passenger should mount the vehicle from the left side Always make sure the brake is engaged to ensure the vehicle remains motionless whenever a passenger mounts or dismounts Allow a passenger to ride only in the approved passenger seat Never carry more than one passenger Slow down Control may be more difficult with a passenger on board Allow
66. ernment officials or military per sonnel on assignment outside the country of the selling dealer s authorized location This policy does not apply to Safety Recalls How to Get Service In the Country where your vehicle was purchased Warranty or Service Bulletin repairs must be done by an authorized Polaris dealer If you move or are traveling within the country where your vehicle was purchased Warranty or Service Bulletin repairs may be requested from any authorized Polaris dealer who sells the same line as your vehicle Outside the Country where your vehicle was purchased If you are traveling temporarily outside the country where your vehicle was purchased you should take your vehicle to an authorized Polaris dealer You must show the dealer photo identification from the country of the selling dealer s authorized location as proof of residence Upon residence verification the servicing dealer will be authorized to per form the warranty repair If You Move If you move to another country be sure to contact Polaris Customer Assistance and the customs department of the destination country before you move Vehicles importation rules vary considerably from country to country You may be required to present docu mentation of your move to Polaris Industries in order to continue your warranty cover age You may also be required to obtain documentation from Polaris Industries in order to register your vehicle in your new country 141
67. g on unfamiliar terrain Always be alert to changing terrain conditions Operating Improperly in Reverse Improperly operating in reverse could result in a collision with an obstacle or person Always follow proper operating procedures as outlined in this manual See page 70 Before shifting into reverse gear always check for obstacles or people behind the ATV When it s safe to proceed back slowly 17 SAFETV Safetv Warnings Improper Tire Maintenance Operating this ATV with improper tires or with improper or uneven tire pressure could cause loss of control or accident Alwavs use the size and tvpe of tires specified for vour ATV Alwavs maintain proper tire pressure as described in the owner s manual and on safetv labels Operating Over Obstacles Improperly operating over obstacles could cause loss of control or overturn Before operating in a new area check for obstacles Avoid operating over large obstacles such as rocks and fallen trees If unavoidable use extreme caution and always follow proper operating procedures as outlined in this manual See page 69 Skidding or Sliding Skidding or sliding can cause loss of control or overturn if tires regain traction unexpectedly On slippery surfaces such as ice or loose gravel travel slowly and use extra caution to reduce the chance of skidding or sliding Do not operate on excessively slippery surfaces 18 SAFETV Safetv Warnings Operat
68. gher than the front Block the wheels 8 Place the transmission in PARK Lock the parking brake Repeat steps 4 to 6 until no more particles are expelled 9 Stop the engine Allow the arrestor to cool 10 Reinstall the arrestor plug and remove the exhaust outlet cover or plug 109 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 will cause the system to be out of balance creating vibration and additional loads on components The PVT system rotates at high speeds creating large amounts of force on clutch components Extensive engineering and testing has been conducted to ensure the safety of this product However as the owner you have the following responsibilities to make sure this system remains safe Always follow all recommended maintenance procedures See your dealer as outlined in the owner s manual This PVT system is intended for use on Polaris products only Do not install it in any other product Always make sure the PVT housing is securely in place during operation 110 MAINTENANCE PVT System When To Use Low Range and High Range The air temperature in the clutch cover is substantially reduced by using low range while operating at low g
69. ght side of the ATV behind the footwell The drain plug is located on the bottom left side of the gearcase Oil Check 1 Remove the footwell see page 97 2 Remove the fill plug Check lt O i the oil level Fill Plug Drain Plug 3 Add the recommended fluid as needed to bring the level to the bottom of the fill hole threads 4 Reinstall the fill plug Torque to specification 5 Reinstall the footwell Oil Change 1 Remove the footwell 2 Place a drain pan under the gearcase Remove the drain plug Allow the oil to drain completely oS Clean and reinstall the drain plug Torque to specification Remove the fill plug Add the proper amount of the recommended oil B Reinstall the fill plug Torque to specification Check for leaks Reinstall the footwell Dispose of used oil properly Qo ON A 86 MAINTENANCE Front Gearcase Demand Drive Fluid See the table on page 81 for fluid recommendations capacities and plug torques Always check and change the demand drive fluid at the inter vals outlined in the Periodic Maintenance Chart beginning on page 77 See page 133 for the part numbers of Polaris products Use the recommended fluid Use of other fluids may result in improper operation of components Maintain the fluid level at the bottom of the fill hole threads See below for capacity The fill plug is located on the right side of the 5 demand drive unit The drain plug is locate
70. hot spot that will shorten the life of the lamp If fingers do touch a lamp clean it with denatured alcohol 1 Remove the five 5 headlight pod screws 2 Liftthe pod cover and disconnect the speedom eter harnesses from the speedometer CAUTION Hot components can cause burns to skin Allow lamps to cool before servicing 3 Unplug the headlamp from the wiring harness Be sure to pull on the connector not on the wir ing 4 Turn the lamp counterclockwise to remove it 5 Install the new lamp Make sure the tab on the lamp locates properly in the housing 6 Reassemble the pod 102 MAINTENANCE Lights High Beam Adjustment The headlight beam can be adjusted slightly upward or downward Use the following procedure to make the adjustment 25 ft 7 6 m Lamp Center Height a 5 cm Position the vehicle on a level surface with the headlight approxi mately 25 ft 7 6 m from a wall Place the transmission in PARK Measure the distance from the floor to the center of the headlight and make a mark on the wall at the same height Start the engine Turn the headlight switch to high beam Observe the headlight aim on the wall The most intense part of the headlight beam should be two inches 5 cm below the mark on the wall Include rider weight on the seat when measuring The adjustment screw is located on the right side of the headlight pod To adjust the beam loosen the screw Adju
71. 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 4X4 Indicator This indicator illuminates when the 4X4 system is engaged switch is on either ADC 4X4 or 4X4 Turf Mode Indicator This indicator illuminates when Turf Mode is engaged EPS Warning Indicator This indicator illuminates when the key is turned to the ON position and goes off when the engine is started If the light remains on after starting the engine the EPS system is inoperative See your authorized Polaris dealer for service 45 FEATURES AND CONTROLS Instrument Cluster Rider Information Center Speed Displav Area Use the MODE button to toggle through the speed displav options MODE button operation is locked out at speeds above approximatelv 15 MPH 25 km h Tip The reverse override button also acts as a MODE button when held down for approximately one half second The transmission cannot be in reverse when using the over ride button as a MODE button MODE SELECT This feature does not contain a Button Button vehicle speed lockout function and can be used at any operating speed Ground Speed Mode Ground speed is displayed in either miles per hour MPH or kilometers per hour km h Engine Speed Mode Engine speed is displayed in revolutions per minute RPM 46 FEATURES AND CONTROLS Instrument Cluster Rider Information Center Info
72. ing Through Deep Water Operating the ATV through deep or fast flowing water could cause the tires to float causing loss of control or overturn Avoid operating the ATV through deep or fast flowing water If it s unavoidable to enter water that exceeds the recommended maximum depth see page 68 Travel slowly Balance your weight carefully Avoid sudden movements Maintain a slow and steady forward motion Do not make sudden turns or stops and do not make sudden throttle changes Wet brakes may have reduced stopping ability After leaving water test the brakes Apply them lightly several times while driving The friction will help dry out the pads Improper Cargo Loading Overloading the ATV or carrying towing cargo improperly may cause changes in handling which could cause loss of control or an accident Never exceed the stated load capacity for this ATV Cargo should be properly distributed and securely attached Reduce speed when carrying cargo or pulling a trailer Allow a greater distance for braking Always follow the instructions in the owner s manual for carrying cargo or pulling a trailer Always follow the instructions in the owner s manual for operating with a passenger See page 60 19 SAFETV Safetv Warnings Operating on Frozen Bodies of Water Operating on frozen bodies of water mav result in serious injurv or death if the ATV and or riders fall through the ice
73. ing indicator appears in the display 3 A set of two numbers will also appear in the display The 2 6 digit suspect parameter number SPN in the information area indicates which component is generating the fault code The 1 2 digit failure mode indicator FMI number in the clock area indi cates the fault mode such as open or short circuit 4 See pages 50 51 for code definitions and failure descriptions Tip More than one fault may be active Press and hold the MODE button to tog gle through all currently active diagnostic codes 49 FEATURES AND CONTROLS Instrument Cluster Rider Information Center Diagnostic Displav Code Definitions Open Load There is a break in the wires that lead to the item listed in the chart injector fuel pump etc or the item has failed Short to Ground The wire is shorted to ground between the electronic control unit and the item listed in the chart Shorted Load The wires leading to the item listed in the chart are shorted together or the item has shorted internallv Short to Batterv The wire leading from the item listed in the chart to the electronic control unit is shorted to a wire at batterv voltage 50 FEATURES AND CONTROLS Instrument Cluster Rider Information Center Sportsman X2 550 EFI Diagnostic Codes Component Condition SPN FMI Throttle Position
74. ion of this manual Cargo weight should be mounted as low as possible When operating over rough or hillv terrain reduce speed and cargo weight to main tain stable driving condi tions 1 Always load the cargo box with the load as far forward as possible 2 Do not obstruct the headlight beam with cargo 3 Use low forward gear when hauling or towing heavy cargo to extend belt life 4 Always operate the vehicle with extreme caution whenever hauling or towing loads Balance handling and control may be affected 5 Slow down 6 Make sure the cargo box dump latch is securely latched before load ing and operating Unintentional dumping will result if weight is placed in the rear of the box and the latch is not secured 73 OPERATION Hauling Cargo Towing Loads Alwavs attach a towed load to the hitch point Remove the hitch from the ATV when not towing a trailer If towing a load reduce rear rack cargo weight bv the amount of tongue weight The combination of rear rack cargo weight and tongue weight must not exceed the rear rack capacity The total load operator passenger accessories cargo and weight on hitch must not exceed the maximum weight capacity of the vehicle NOTICE Using an improper hitch or exceeding the maximum tongue Maximum weight capacity can result in serious 4 10 cm damage to the vehicle and will void your ATV warranty Never install a hitch longer than 4 10 cm Never insta
75. ive emission control system 143 WARRANTV U S A EPA Emissions Limited Warrantv The exclusive remedy for breach of this limited warranty shall be at the exclusive option of Polaris repair or replacement of any defective materials components or prod ucts THE REMEDIES SET FORTH IN THIS LIMITED WARRANTY ARE THE ONLY REMEDIES AVAILABLE TO ANY PERSON FOR BREACH OF THIS WAR RANTY POLARIS SHALL HAVE NO LIABILITY TO ANY PERSON FOR INCI DENTAL CONSEQUENTIAL OR SPECIAL DAMAGES OF ANY DESCRIPTION WHETHER ARISING OUT OF EXPRESS OR IMPLIED WAR RANTY OR ANY OTHER CONTRACT NEGLIGENCE OR OTHER TORT OR OTHERWISE ALL IMPLIED WARRANTIES INCLUDING BUT NOT LIMITED TO ANY IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PAR TICULAR PURPOSE ARE LIMITED IN DURATION TO THE WARRANTY PERIOD DESCRIBED HEREIN POLARIS DISCLAIMS ALL EXPRESS WARRAN TIES NOT STATED IN THIS WARRANTY Some states do not allow limitations on how long an implied warranty lasts so the above limitation may not apply if it is incon sistent with the controlling state law This limited warranty excludes failures not caused by a defect in material or workman ship This limited warranty does not cover damage due to accidents abuse or improper handling maintenance or use This limited warranty also does not cover any engine that has been structurally altered or when the vehicle has been used in racing competition This limited warranty also does not cover physical damage
76. l Brake Fluid Check the brake fluid level fre Reservoir quently for the auxiliary brake sys tem The reservoir is located under the front rack Maintain the fluid level between the maximum and minimum marks Use DOT 4 brake fluid only NOTICE Do not use ADC fluid in the brake fluid reservoir ADC fluid will damage the rubber components of the brake system 34 FEATURES AND CONTROLS Automatic Transmission Gear Selector The transmission gear selector is Gear located on the right side of the vehi Selector cle High Gear Low Gear Neutral Reverse Park To shift gears brake to a complete stop When the engine is idling move the lever to the desired gear NOTICE Shifting gears with the engine speed above idle or while the vehicle is moving could cause transmission damage Whenever the ATV is left unattended always place the transmission in PARK and lock the parking brake Belt Life To extend belt life use low forward gear in heavy pulling situations and when operating at less than seven miles per hour for extended periods of time SEZUT 35 FEATURES AND CONTROLS All Wheel Drive System The All Wheel Drive system is controlled by the 4X4 switch ADC 4X4 Mode When the switch is on ADC 4XA the ADC system allows engine braking to all four wheels when the vehicle descends a hill or incline Always move the 4X4 switch to ADC 4X4 before ascending or descending a hill See page 38 4X4 M
77. l electri cal power to the vehicle including lights 28 FEATURES AND CONTROLS Switches Main Kev Switch Use the main kev switch to start the engine See page 57 4X4 Switch Use the 4X4 switch to engage ADC 4X4 4X4 2X4 or TURF mode See page 38 The vehicle automatically engages 4X4 when operating in reverse if the switch is set to either 4X4 position Headlight Switch Use the headlight switch to turn the lights on and off and to change the lights from high beam to low beam The key must be in the ON position and the engine stop switch must be in the RUN position to operate the headlights 29 FEATURES AND CONTROLS Throttle Lever A WARNING Operating an ATV with sticking or improperly operating throttle controls could cause an accident Never start or operate an ATV that has a sticking or improperly operating throttle Always contact your dealer for service before operating the vehicle Failure to check or maintain proper operation of the throttle system can result in an accident if the throttle lever sticks during operation Always check the lever for free movement and return before starting the engine Also check occasionally during operation Modifications to the electronic throttle control could result in failure to perform as designed which could result in an accident Do not attempt to modify the throttle control system or replace it with any after market throttle mechanisms Always ensure that the throttle cable i
78. le Climbing a Hill 16 Turning Improperlv 14 Unauthorized Use 21 Unfamiliar Terrain 17 Using Alcohol or Drugs 12 Seat Removal 97 Severe Use cobre dices es TI Side Panel Removal 97 Sidehilling LL 64 Signal Words 4 Spark Arrestor 0000 109 Spark Plug Inspection 106 107 Spark Plug Recommendations 106 Spark Plugs 106 107 Spring Adjustment Shock 121 Standard Metric Display 47 Starting the Engine 57 Steering Assemblv 96 Storage 123 128 Storage Tips 126 128 S Switches 0 ee eee 28 29 4X4 Switch nuuanu 29 Engine Stop Switch 28 Headlight Switch 29 Main Kev Switch 29 Mode Reverse Override Switch 28 T Taillight Lamp Replacement 105 Throttle Bodv Adjustment 118 Throttle Cable Freeplav 118 119 Throttle Lever 00000000 30 Tire Tread Depth 98 dares io tm 98 99 Wheel Installation 99 Wheel Nut Torque 99 Wheel Removal 98 Toe Alignment 96 Towing Capacities 74 Towing Loads 74 Trail Etiquette 56 Tramgsced r eee REPE 7 Transmission 35 Transmission Oil 86 Transporting the ATV 122 Tread Lightly 56 Turning Around on a Hill
79. ll automotive accessories on your Polaris ATV Always install Polaris approved or equivalent accessories designed for ATV use Maximum Towing Capacities Do not exceed the following maximum capacities when towing Avoid towing on inclines Sportsman X2 550 EFI Maximum Towed Load Level Ground 1500 Ibs 680 kg Maximum Vertical Hitch Weight 150 Ibs 68 kg 74 OPERATION Hauling Cargo Dumping Cargo 1 Select a level site to dump the cargo box Do not attempt to dump or unload the vehicle while parked on an incline 2 Place the transmission in PARK 3 Lock the parking brake 4 Dismount the vehicle 5 Lower the tailgate WARNING If cargo weight is placed toward the rear of the cargo box the load may dump unexpectedly and cause serious injury When loading cargo always position the weight as far forward and as low as possible 6 Pull the cargo box release lever upward 7 Liftthe front of the cargo box and dump the cargo 8 Lower the cargo box and make Dump Box sure the release latch is Release secured Latch 9 Secure the tailgate WARNING Operating with the cargo box in the raised position can cause serious injury and damage to the vehicle The cargo box could close unexpectedly and injure the driver The rear tires will also catch the rear of the bed damaging the vehicle and creating hazardous driving conditions Never operate this vehicle with the cargo box
80. lt in an accident or fire Always check to be sure the parking brake is disengaged before operating The parking brake may relax if left on for a long period of time Always block the wheels to prevent rolling Always block the wheels on the downhill side of the ATV if leaving it parked on a hill Another option is to park the ATV in a sidehill position Never depend on the parking brake alone if the ATV is parked on a hill Always block the wheels to prevent rolling 33 FEATURES AND CONTROLS Auxiliary Foot Brake A WARNING Aggressively applying the auxiliary brake when backing down a hill may cause rear tipover which could result in serious injury or death Never back down a hill Use caution when applying the auxiliary brake Do not aggressively apply the auxiliary brake when going forward The rear wheels may skid and slide sideways causing loss of control and serious injury or death The auxiliary brake system is intended to be used as a backup for the main brake system Should the main system fail use the aux iliarv foot brake Since this is a rear brake only it will not be as effective as the all wheel single lever system The auxiliary foot brake is located on the inside of the right footrest Operate this brake with your right foot Auxiliary If the rear wheels slide while Foot Brake using the auxiliary brake reduce brake pedal pressure to brake the rear wheels without skidding Brake Fluid Leve
81. m line and repeat step 6 before proceeding 7 8 Torque the valves to 80 in lbs 9 Nm Reinstall the valve caps Add fresh ADC fluid to the reservoir until the level is between the minimum and maximum marks Make sure the reservoir is free of debris Reinstall the cap securely Clean up any drips or spills 91 MAINTENANCE Cooling Svstem The engine coolant level is controlled or maintained bv the recoverv svstem The recoverv svstem components are the recoverv 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 recoverv bottle As engine coolant temperature decreases the con tracting cooled coolant is drawn back up from the bottle past the pres sure cap and into the radiator Some coolant level drop on new vehicles is normal as the svstem is purging itself of trapped air Check the coolant level and maintain as recommended bv adding coolant to the recoverv bottle Polaris recommends the use of Polaris Premium 60 40 anti freeze cool ant or a 50 50 mixture of high quality aluminum compatible anti freeze coolant and distilled water Polaris Premium 60 40 is already premixed and ready to use Do not dilute with water See page 133 for the part numbers of Polaris products Always follow the manufacturer s mixing recommendations for the freez
82. manufac turer s instructions for recharging When using a constant current charger use the guidelines on the next page for recharging 116 Batterv MAINTENANCE Batterv Charging Sealed Batterv Always verify battery condition before and 1 2 hours after the end of charging State of Charge Time Voltage Action Using constant current Charge charger standard amps specified on top of battery 100 12 8 13 0 volts None check at 3 None required mos from date of manufacture 75 100 12 5 12 8 volts May need slight 3 6 hours charge if no charge given check in 3 months 5 11 hours 50 75 12 0 12 5 volts Needs charge 25 50 11 5 12 0 volts Needs charge At least 13 hours verify state of charge 096 2596 11 5 volts or less Needs charge with desulfating charger At least 20 hours 117 MAINTENANCE Throttle Body ldle RPM Idle RPM is preset by the manufacturer If the engine idle speed is not satisfactory please see your Polaris dealer for adjustment Throttle Cable Freeplay 1 Remove the four cover screws from the right han dlebar control and remove the cover 2 With the handlebars straight ahead place very light pressure on the throt tle lever A gap of 2 3 mm should be visible between the throttle arm stop pin and the throttle arm If adjustment is needed 1 Locate the throttle cable Canis adjuster Squeeze the end Adjuster of the rubbe
83. n forward Release the parking brake and proceed s owly controlling speed with the brake lever until the vehicle 1s on more level ground 67 OPERATION Driving Through Water Your ATV can operate through water with a maximum recommended depth equal to the bottom of the footrests Follow these procedures when operating through water 1 Determine water depths and current before entering water 2 Choosea crossing where both banks have gradual inclines 3 Avoid operating through deep or fast flowing water NOTICE Major engine damage can result if the vehicle is not thoroughly inspected after operation in water Perform the services outlined in the maintenance chart See page 77 The following areas need special attention engine oil transmission oil demand drive fluid and all grease fittings If the vehicle tips or overturns in water or if the engine stops during or after operating in water restarting can result in serious engine damage Transport the vehicle to your dealer for service before restarting the engine If this is not possible follow the vehicle immersion inspection and drying procedures outlined on page 108 then see your dealer for service at the first opportunity 4 After leaving water test the brakes Apply them lightly several times while driving slowly The friction will help dry out the pads If it s unavoidable to enter water deeper than the footrest level Proceed slowly Avoid rocks and obstacles
84. n your total satisfaction Be sure to return to your dealership for all of your ser vice needs during and after the warranty period We also take great pride in our complete line of apparel parts and acces sories available through our online store at www purepolaris com Have your accessories and clothing delivered right to your door POLARIS The Way Out POLARIS and POLARIS THE WAY OUT are registered trademarks of Polaris Indus tries Inc Copyright 2009 Polaris Sales Inc All information contained within this publication is based on the latest product information at the time of publication Due to constant improvements in the design and quality of production components some minor discrep ancies may result between the actual vehicle and the information presented in this publi cation Depictions and or procedures in this publication are intended for reference use only No liability can be accepted for omissions or inaccuracies Any reprinting or reuse of the depictions and or procedures contained within whether whole or in part is expressly prohibited Printed in U S A 2010 Sportsman X2 550 EFI Owner s Manual P N 9922051 2 TABLE OF CONTENTS Introduction x2 sk urhe Rs cee eee ba fu 4 sri de PEDE 7 Features and Controls 28 Operation ta sx EXUUEEIO e sees 52 Emission Control Systems 76 Maintenance tesi venta nex mri pde he 77 Troubleshooting 129 Polaris Products
85. needed Headlight taillight Daily Check operation apply dielectric grease if replacing lamps 78 Periodic Maintenance Chart MAINTENANCE Item Maintenance Interval Remarks whichever comes first Hours Calendar Miles Km gt Air filter Weekly Inspect replace as needed E main element gt Engine oil change 20H 1 Month 500 800 JPerform a break in oil and filter change see page 84 gt Brake pad wear 10H Monthly 100 160 Inspect periodically a Battery 20H Monthly 200 320 Check terminals clean test E ADC fluid 25 H Change fluid if extreme use conditions see page 90 gt Rear gearcase oil 25 H Monthly 250 400 Inspect level change yearly gt Transmission oil 25 H Monthly 250 400 Inspect level change yearly gt Demand drive fluid 25 H Monthly 250 400 Inspect level change yearly gt General 50 H 3M 500 800 Lubricate all fittings pivots lubrication cables etc Shift linkage 50 H 6M 500 800 Inspect lubricate E Steering 50 H 6M 500 800 Lubricate gt Front suspension 50 H 6M 500 800 JLubricate gt Rear suspension 50 H 6M 500 800 Lubricate E Throttle Cable 50 H 6M 500 800 Inspect adjust lubricate E JETC Switch replace if necessarv E Throttle Body 50 H 6M 500 800 Inspect duct for proper seal Intake Duct ing air leaks Drive belt 50 H 6M 500 800 Inspect adj
86. ode When the switch is on 4X4 the ATV is in 4X4 and the 4X4 indica tor light in the instrument cluster will be on When in 4X4 the demand drive unit will automatically engage any time the rear wheels lose traction When the rear wheels regain trac tion the demand drive unit will automatically disengage There is no limit to the length of time the vehicle may remain in 4X4 ADC 4X4 4y4 2x4 4x4 TURF Tip The override switch allows activation of 4X4 in reverse if the 4X4 switch is on See page 28 36 FEATURES AND CONTROLS All Wheel Drive System 2X4 Mode When the switch is on 2X4 the ATV is in two wheel drive at all times TURF Mode When operating in TURF mode the inside rear wheel will rotate inde pendently from the outside wheel during turns Operate in TURF mode only as needed to protect smooth level surfaces from tire damage DO NOT operate in TURF mode when climbing or descending hills when sidehilling or when operating on uneven loose or slippery terrain such as sand gravel ice snow obstacles and water crossings Always oper ate in ADC 4X4 or 4X4 on these types of terrain WARNING Operating in TURF mode when on sloped uneven or loose terrain could cause loss of control and result in serious injury or death One rear wheel may slip and lose traction or may lift up and grab when it touches the ground again Engaging 4X4 The 4X4 switch may be turned on or off while the vehicle 1s m
87. of the ATV to the transporting unit securely with suitable straps or rope Do not attach tie straps to the front A arm bolt pockets 7 Remove the key to prevent loss during transporting n 5 zu IA SS 33 SABTA S S 33 4 M JA kal 3s gt 122 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 Usea professional type washing cloth cleaning the upper body first and the lower parts last 2 Rinse with clean water frequently 3 Dry surfaces with a chamois to prevent water spots Washing Tips Avoid the use of harsh cleaners which can scratch the finish Do not use a power washer to clean the vehicle Do not use medium to heavy duty compounds on the finish Always use clean cloths and pads for cleaning and polishing Old or reused cloths and pads may contain dirt particles that will scratch the finish 123
88. ontrol accident or overturn which may result in serious injury or death Read and understand all safety warnings outlined in the safety section of this owner s manual Break In Period The break in period for your new Polaris ATV is the first ten hours of operation or the time it takes to use the first two full tanks of gasoline No single action on your part is as important as following the proce dures for a proper break in Careful treatment of a new engine and drive components will result in more efficient performance and longer life for these components NOTICE Excessive heat build up during the first three hours of operation will damage close fitted engine parts and drive components Do not operate at full throttle or high speeds during the first three hours of use 52 OPERATION Break In Period Engine and Drivetrain Break in 1 2 Fill the fuel tank with gasoline See page 39 Always exercise extreme caution whenever handling gasoline Check the engine oil level on the dipstick See page 82 Add oil if necessary to maintain the level between the safe and add marks Drive slowly at first Select an open area that allows room to famil iarize yourself with vehicle operation and handling Vary the throttle positions Do not operate at sustained idle Perform regular checks on fluid levels controls and areas outlined on the daily pre ride inspection checklist See page 54 Pull only light loads Change both th
89. or the correct replacement part 5 Reinstall the front rack Radiator Cap 94 MAINTENANCE Brakes Hand Brake The front and rear brakes are hvdraulic disc brakes activated bv moving the single brake lever toward the handlebar These brakes are self adjusting Under normal operation the diaphragm extends into the reservoir as fluid level drops If the fluid level is low and the diaphragm is not extended a leak is likelv and the diaphragm should be replaced To ensure proper diaphragm operation alwavs fill the reservoir as needed whenever the cover is loosened or removed Do not overfill WARNING An over full master cylinder may cause brake drag or brake lock up which could result in serious injury or death Maintain brake fluid at the recommended level Do not overfill The following checks are recommended to keep the brake system in good operating condition Check more often if brakes are used heavily under normal operation 1 Always keep brake fluid at an adequate level See page 32 Check the brake system for fluid leaks 3 Check the brakes for excessive travel or spongy feel 4 Check the friction pads for wear damage and looseness Replace brake pads when they are worn to 3 64 1 mm 5 Check the security and surface condition 3 64 1 mm of the disc Auxiliary Foot Brake The hydraulic auxiliary brake system requires no adjustment Check the brake fluid level frequently for
90. ot operate vehicle with guard removed Do not modify engine or clutch Doing so can cause part failure possible imbalance and excessive engine RPM which can result in serious injury or death 7172563 26 Safetv Labels and Locations Box Warning WARNING Remove flammable material containers from box before filling WARNING Passengers can be thrown off This can cause serious injurv or death Never carrv passengers in cargo box Maximum Box Load 400 Ibs 181 kg 7173890 27 FEATURES AND CONTROLS Switches Headlight Switch Mode Reverse Override Button Engine Main Key Stop Switch Switch Mode Reverse Override Switch This vehicle is equipped with a reverse speed limiter system To gain additional wheel speed while backing depress the override switch WARNING Activating the override switch while the throttle is open can cause loss of control which may result in serious injury or death Always release the throttle before activating the override switch The override switch also allows activation of 4X4 in reverse if the 4X4 switch is on This switch is also used to toggle through the modes of the rider information center See page 43 Engine Stop Switch Move the stop switch either left or right to ar TA the OFF position to stop the engine quickly LL The engine will not start or run when the OFF RUN OFF switch is off gt Both the main switch and the engine stop switch will shut off al
91. our dealer Other mechanical failure Possible Lean Fuel Cause Low or contaminated fuel See vour dealer Solution Add or change fuel clean the fuel svstem Kinked or plugged fuel tank vent line Inspect and replace Low octane fuel Replace with recommended fuel Clogged fuel filter See vour dealer Incorrect fuel Possible Rich Fuel Cause Fuel is verv high octane Replace with recommended fuel Solution Replace with lower octane fuel Stopping starting without adequate warm up Allow engine to warm up before operat ing and or stopping Incorrect fuel Replace with recommended fuel Clogged air filter Inspect and clean or replace 131 TROUBLESHOOTING Engine Stops or Loses Power Possible Cause Solution Out of fuel Refuel cycle key to ON position three times for 5 seconds each then start Kinked or plugged fuel vent line Inspect and replace Water is present in fuel Replace with new fuel Fouled or defective spark plug s 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
92. oving Initially the vehicle s electronic system will not enable 4X4 until the engine RPM is below 3100 Once enabled 4X4 remains enabled until the 4X4 switch is turned off If the switch is turned off while the demand drive unit is moving it will not disengage until the rear wheels regain traction Engage the 4X4 switch before getting into conditions where front wheel drive may be needed If the rear wheels are spinning release the throttle before switching to 4X4 NOTICE Switching to 4X4 or ADC 4X4 while the rear wheels are spinning may cause severe drive shaft and gearcase damage Always switch to 4X4 or ADC 4X4 while the rear wheels have traction or are at rest 37 FEATURES AND CONTROLS Active Descent Control ADC Svstem The ADC svstem allows engine braking to all four wheels when the Vehicle descends a hill or incline Alwavs move the 4X4 switch to ADC AXA before ascending or descending a hill Engaging Active Descent Control The ADC svstem will automaticallv engage when all four of the follow ing conditions occur The 4X4 switch must be in the ADC 4X4 position Vehicle speed must be 15 mph 24 km h or less The throttle must be closed throttle lever released The transmission must be in gear high low or reverse Disengaging Active Descent Control The ADC system will automatically disengage if at least one of the fol lowing conditions occur The 4X4 switch is moved out of the ADC 4X4 position Vehi
93. pean direc tives 97 24 EC and 2004 108 EC 76 MAINTENANCE Periodic Maintenance Chart Careful periodic maintenance will help keep vour vehicle in the safest most reliable condition Inspection adjustment and lubrication of important components are explained in the periodic maintenance chart Inspect clean lubricate adjust and replace parts as necessarv When inspection reveals the need for replacement parts use genuine Polaris parts available from vour Polaris dealer Record maintenance and service in the Maintenance Log beginning on page 145 Service and adjustments are important for proper vehicle operation If you re not familiar with safe service and adjustment procedures have a qualified dealer perform these operations Maintenance intervals in the following chart are based upon average riding conditions and an average vehicle speed of approximately 10 miles per hour Vehicles subjected to severe use must be inspected and serviced more frequently Severe Use Definition Frequent immersion in mud water or sand Racing or race style high RPM use Prolonged low speed heavy load operation Extended idle Short trip cold weather operation Pay special attention to the oil level A rise in oil level during cold weather can indicate contaminants collecting in the oil sump or crank case Change oil immediately if the oil level begins to rise Monitor the oil level and if it continues to rise discontinue use and de
94. pellents 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 43 FEATURES AND CONTROLS Instrument Cluster Rider Information Center The rider information center is located in the instrument cluster All seg ments will light up for one second at start up If the instrument cluster fails to illuminate a batterv over voltage mav have occurred and the instrument cluster mav have shut off to protect the electronic speedome ter If this occurs take the ATV to vour Polaris dealer for proper diagno sis 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 47 1 2 3 4 13 12 11 7 10 9 9 8 1 Gear Indicator This indicator displays gear shifter position H High Gear L Low Gear N Neutral R Reverse Gear P Park Gear Signal Error or shifter between gears 2 Information Display Area This area displays odometer tripme ters engine hour meter and programmable service hour interval 3 Speed Display This area displays vehicle ground speed or engine rotational speed when the corresponding display is selected See page 46 44 FEATURES AND CONTROLS Instrument Cluster Rider Information Center 4
95. precautions Readthis 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 This vehicle is an ADULT VEHICLE ONLY Operation is prohibited for anyone under 16 years of age Never permit a guest to operate the ATV unless the guest has read this manual and all product labels and has completed a certified safety training course INTRODUCTION Vehicle Identification Numbers Record vour vehicle s identification numbers and kev number in the spaces provided Remove the spare kev and store it in a safe place An ignition key can be duplicated only by ordering a Polaris key blank using your key number and mating it with one of your existing keys The ignition switch must be replaced if all keys are lost Engine Serial Number Key Number Vehicle Model Number Frame VIN Engine Serial Number Key Number SAFETV Safetv Training ATV safetv training is a top prioritv for Polaris Polaris stronglv encourages vou and anv familv members who will be riding the ATV to take a training course If vou purchased a new Polaris ATV in the United States vour dealer provided instruction to you about the authorized ATV RiderCourse that is available to you and your eligible family members This training is included in the purchase price of your ATV You we
96. r boot and slide it back far enough to expose the in line cable adjuster locknut Arm Stop Pin 2 3 mm Gap 2 Loosen the adjuster lock nut 3 Rotate the boot to turn the adjuster until 2 3 mm of freeplay is achieved between the stop pin and the throttle arm While Boot adjusting freeplay flip the throttle lever back and forth repeatedly continued on next page Lock Nut Adjuster 118 MAINTENANCE Throttle Cable Freeplav 4 2 6 10 Place the transmission in PARK Lock the parking brake Start the engine and allow the idle to stabilize If necessary tap the throttle lever to ensure the idle speed settles If idle speed remains above or below the recommended setting see specification pages verify the correct gap If gap is correct and idle speed is still not satisfactory please see your Polaris dealer for ser vice With the engine running turn the handlebars fully to the left and right Tap the throttle lever at each turn verifying that idle RPM returns to the recommended setting If idle speed increases it may be necessary to increase the gap between the stop pin and throttle arm but do not exceed the recommended 2 3 mm gap When adjustments are complete tighten the locknut Squeeze the end of the rubber boot and slide it over the cable adjuster to its original position Ensure the control cover seal is in place then reinstall the cover and screws 119 MAINTENANCE Handlebars
97. re also provided with printed materials that explain safe operating procedures You should review this information on a regular basis If you purchased a used Polaris ATV in the United States you can enroll in the ATV RiderCourse for a fee Call ATV Enrollment Express at 800 887 2887 or visit www atvsafety org If you purchased a Polaris ATV outside the United States please contact your dealer or local law enforcement agencies for information about safety training A Polaris ATV is an off road vehicle Familiarize yourself with all laws and regulations concerning the operation of this vehicle in your area We strongly advise you to strictly follow the recommended maintenance program outlined in your owner s manual This preventive maintenance program is designed to ensure that all critical components on your vehicle are thoroughly inspected at specific intervals FOR MORE INFORMATION ABOUT ATV SAFETY in the United States call the Consumer Product Safety Commission at 1 800 638 2772 or visit www cpsc gov visit www atvsafety org or call Polaris at 1 800 342 3764 SAFETV Safe Riding Gear Alwavs wear appropriate clothing when riding an ATV Wear protective clothing for comfort and to reduce the chance of injury Helmet CES pu 5 RS Gloves Eye Protection 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 stan
98. resolve any warranty issues Should your dealer require any additional assistance they will contact the appropriate person at Polaris This warranty gives you specific legal rights and you may also have other rights which vary from state to state If any of the above terms are void because of state or federal law all other warranty terms will remain in effect Engine Oil 1 Mixing oil brands or using non recommended oil may cause engine damage We rec ommend the use of Polaris engine oil for your ATV 2 Damage resulting from the use of non recommended lubricants may not be covered by warranty SPARK ARRESTOR Polaris warrants that the spark arrestor in this vehicle will meet the efficiency require ments of 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 140 WARRANTV Exported Vehicles EXCEPT WHERE SPECIFICALLV REQUIRED BV LAW THERE IS NO WAR RANTY OR SERVICE BULLETIN COVERAGE ON THIS VEHICLE IF IT IS SOLD OUTSIDE THE COUNTRY OF THE SELLING DEALER S AUTHORIZED LOCA TION This policy does not apply to vehicles that have received authorization for export from Polaris Industries Dealers may not give authorization for export You should consult an authorized dealer to determine this vehicle s warranty or service bulletin coverage if you have any questions This policy does not apply to vehicles registered to gov
99. rformed by your authorized Polaris dealer Wheel Removal 1 Stop the engine 2 Place the transmission in PARK 3 Lock the parking brake 4 Loosen the wheel nuts slightly WARNING Do not service axle nuts that have a cotter pin installed See your Polaris dealer 5 Elevate the side of the vehicle by placing a suitable stand under the footrest frame 6 Remove the wheel nuts 7 Remove the wheel 98 MAINTENANCE Tires Wheel Installation 1 Place the transmission in PARK 2 Lock the parking brake 3 Place the wheel on the hub with the valve stem toward the outside and rotation arrows on the tire pointing toward forward rotation if equipped 4 Install the wheel nuts and finger tighten them 5 Lower the vehicle to the ground 6 Torque the wheel nuts to specification WARNING Loose nuts could cause a tire to come off during operation which could result in an accident or overturn Always ensure that all nuts are torqued to specification 75 ft Ibs 102 Nm Cast Aluminum Steel 45 ft Ibs 61 Nm Wheel Nut Torque Specifications Check the wheel nut torques occasionally and when they ve been loos ened for service Wheel Type Nut Type Nut Torque Aluminum Lug Nut 75 ft Ibs 102 Nm Steel Lug Nut 45 ft Ibs 61 Nm 99 MAINTENANCE Air Filter 1 Remove the seat See page 97 Pre Filter 2 Remove the air box cover d screws and remove the air Pan Main Fil
100. rmation Displav Area Use the SELECT button SEL to toggle through the information area options SELECT button operation is locked out at speeds above approximatelv 15 MPH 25 km h Tip The reverse override button also acts as the SELECT button when pressed and released quickiv The transmission cannot be in reverse when using the override button as a SELECT button This feature does not contain a vehi cle speed lockout function and can be used at anv operating speed Standard Metric Displav The displav can be viewed in either standard or metric units of measure ment To change units 1 Press and hold the MODE button until vehicle speed is displayed 2 Toggle through the information area using the SELECT button until the odometer is displayed 3 Press and hold the MODE button until the displayed units change Release the button 4 New settings remain until changed using the same procedure 12 Hour 24 Hour Clock Display 1 Press and hold the MODE button until RPM is displayed 2 Toggle through the information area using the SELECT button until the odometer is displayed 3 Press and hold the MODE button until the clock displays the new clock format either 24 hour or 12 hour Release the button 4 New settings remain until changed using the same procedure Odometer Mode The odometer records and displays the distance traveled by the ATV Trip Meter Mode The trip meters record the distance traveled by the ATV on ea
101. roper operation 28 Air filter pre filter Inspect clean 100 Air box sediment tube Drain deposits whenever visible Headlamp Check operation apply Polaris dielec 29 tric grease when lamp is replaced 102 Brake light taillight Check operation apply Polaris dielec 105 tric grease when lamp is replaced Riding gear Wear approved helmet goggles and 8 protective clothing ADC Fluid Ensure proper level 90 54 OPERATION Safe Operation Practices 1 2 10 11 12 13 Complete the recommended safety training before operating this vehicle See page 7 Do not allow anyone under 16 years of age to operate this vehicle Do not allow anyone with cognitive or physical disabilities to oper ate this vehicle Engine exhaust fumes are poisonous Never start the engine or let it run in an enclosed area Before operating learn how to use the auxiliary brake for emer gency situations if service brakes become inoperable Operate this vehicle off road only Never operate the vehicle on pavement or on any public street road or highway including dirt and gravel roads Use caution and drive at reduced speeds in conditions of reduced visibility such as fog rain and darkness Clean headlights fre quently and replace burned out headlamps promptly Drive in a manner appropriate for your skills your passenger s skills and operating conditions Never operate at excessive speeds Never attempt wheelies jumps or other stunt
102. round speeds Reducing the tempera ture inside the clutch cover greatly extends the life of the PVT compo nents belt cover etc 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 operat ing 1 Position the vehicle on a level surface 2 Remove the drain plug Allow the water to drain completely Rein stall the drain plug 3 Start the engine Place the transmission in PARK 4 Apply varying throttle for 10 15 seconds to expel the moisture and air dry the belt and clutches Do not hold the throttle wide open for more than 10 seconds 5 Allow the engine RPM to settle to idle speed then shift the trans mission to the lowest available range 6 Test for belt slippage If the belt slips repeat the process 7 Take the vehicle to your dealer for service as soon as possible 111 MAINTENANCE Batterv A WARNING Improperly connecting or disconnecting battery cables can result in an explosion and cause serious injury or death When removing the battery always disconnect the negative black cable first When reinstalling the battery always connect the negative black cable last A WARNING
103. s Never remove your hands from the handlebars while operating and always keep both feet on the footrests Never consume alcohol or drugs before or while operating an ATV Always use the size and type of tires specified for your vehicle Always maintain proper tire pressure Never operate a damaged ATV After any overturn or accident have a qualified service dealer inspect the entire machine for possible damage Never operate the ATV on a frozen body of water Do not touch hot exhaust system components Always keep com bustible materials away from the exhaust system Always remove the ignition key when the vehicle is not in use to prevent unauthorized use 55 OPERATION Know Your Riding Area Tread Lightly Familiarize yourself with all laws and regulations concerning the opera tion of this off road vehicle in your area Respect the environment in which you ride Find out where the designated riding areas are by con tacting your Polaris dealer a local riding club or local officials Help keep our trails open for recreational vehicle use As an off road enthusiast you represent the sport and can set a good example or a poor example for others to follow Tread lightly Operate with respect for the terrain avoid littering and always stay on the designated trails Trail Etiquette Always practice good etiquette when riding Allow a safe distance between your vehicle and other vehicles operating in the same area Communica
104. s properly installed to the throttle control Engine speed and vehicle movement are controlled by pressing the throttle lever The throttle lever is spring loaded Engine speed returns to idle when the lever is released This ATV is equipped with Polaris Electronic Throttle Control ETC which is designed to reduce the risk of a frozen or stuck throttle If the throttle cable should stick in an open position when the operator releases the throttle lever the engine will stop and power to the rear wheels will cease 30 FEATURES AND CONTROLS Brake Lever A WARNING Operating the ATV with a spongy brake lever can result in loss of braking which could cause an accident Never operate the ATV with a spongy feeling brake lever Always contact your dealer for service before operating the vehicle Squeeze the brake lever toward the handlebar to apply the front and rear brakes These brakes are hydraulically activated disc type brakes that are activated by only one lever Always test brake lever travel and master cylinder fluid level before riding When squeezed the lever should feel firm Any sponginess would indicate a possible fluid leak or low master cylinder fluid level which must be corrected before riding Contact your dealer for proper diagnosis and repairs 31 FEATURES AND CONTROLS Master Cvlinder Brake Fluid A WARNING An over full master cylinder may cause brake drag or brake lock up which could result
105. st the headlamp to the desired position then tighten the screw Adjustment Screw 103 MAINTENANCE Lights Low Beam Adjustment The low beam can be adjusted slightly upward or downward l Loosen the phillips screw located at the rear of the headlamp Tilt the headlamp upward or downward Tighten the screw Headlight Housing Replacement l 2 104 Remove the five 5 headlight pod screws Lift the pod cover and disconnect the speedometer harnesses from the speedometer Unplug the headlamp from the wiring harness Use a small screwdriver to remove the o rings from the headlight mounting tabs Pull the headlight housing up to release it from the locking tabs Carefully pull the assembly up and out of the pod Reverse the steps to install the new housing and reassemble the pod MAINTENANCE Lights Lower Headlamp Replacement 1 Turn the back of the headlight harness counterclockwise and pull the harness assembly away from the headlight assembly Remove the headlamp and install the new headlamp Reinstall the harness assembly into the headlight assembly Turn the headlight harness clockwise to secure the head lamp Taillight Brakelight Lamp Replacement l 2 7 8 9 Open the tailgate Remove the two screws near the tailgate latch Grasp the entire taillight assembly and pull it away from the vehicle Remove the harness connector from the back of
106. t be drained Water accu mulation increases as outside temperature decreases See your Polaris dealer for engine heater kits which provide quicker warm ups and easier starting in colder weather 57 OPERATION Driving Procedures Dit ee 22 n oN 10 11 12 58 Wear protective riding gear See page 8 Perform the pre ride inspection See page 54 Place the transmission in PARK Lock the parking brake Mount the vehicle from the left side Sit upright with both feet on the footrests and both hands on the handlebars Start the engine and allow it to warm up Shift the transmission into gear Check your surroundings and determine your path of travel Release the parking brake Slowly depress the throttle with your right thumb and begin driving Drive slowly Practice maneuvering and using the throttle and brakes on level surfaces OPERATION Turning the Vehicle Both rear wheels drive equally at all times except when operating in TURF mode This means that the outside wheel must travel a greater distance than the inside wheel when turning and the inside tire must slip traction slightly 1 Slow down 2 Never turn quickly when carrying a pas senger or cargo 3 Steer in the direction of the turn 4 Keep both feet on the footrests 5 Lean your upper body to the inside of the turn while supporting your weight on the outer footrest This technique alters the balance of traction between the r
107. t 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 130 Engine Pings or Knocks Possible Cause TROUBLESHOOTING Solution Poor qualitv or low octane fuel Replace with recommended fuel Incorrect ignition timing See vour dealer Incorrect spark plug gap or heat range Set gap to specs or replace plugs Engine Runs Irregulariv Stalls or Misfires Possible Cause Solution Fouled or defective spark plug s Inspect clean and or replace spark plug s Worn or defective spark plug wires 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 y
108. te to oncoming operators by signaling the number of vehi cles in your group When stopping move your vehicle to the edge of the trail as far as possible to allow others to pass safely 56 OPERATION Starting the Engine 1 Position the vehicle on a level surface outdoors or in a well venti lated area 2 Place the transmission in PARK 3 Lock the parking brake Tip The starter interlock will prevent the engine from starting if the transmission is in gear and the brake is not engaged 4 Sit on the vehicle and move the engine stop switch to RUN Tip Do not press the throttle while starting the engine 5 Turn the ignition key past the ON position to engage the starter Activate the starter for a maximum of five seconds releasing the key when the engine starts 6 Ifthe engine does not start return the key to the OFF position and wait five seconds before attempting to start again Activate the starter for another five seconds if necessary Repeat this procedure until the engine starts NOTICE Operating the vehicle immediately after starting could cause engine damage Allow the engine to warm up for several minutes before operating the vehicle Cold Weather Operation If the ATV is used year round check the oil level frequently A rising oil level could indicate the accumulation of contaminates such as water or excess fuel in the bottom of the crankcase Water in the bottom of the crankcase can lead to engine damage and mus
109. ter b i ex OX cover G Wa d SS 3 Remove the filter l gs 4 Remove the fabric type pre 3 W 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 1f needed 6 Reinstall the filter into the air box 7 Reinstall the air box cover and the seat 100 MAINTENANCE Fuse Replacement If the engine stops or will not start or if vou experience other electrical failures a fuse mav need replacement Locate and correct anv short cir cuits that mav have caused the blown fuse then replace the fuse Spare fuses are provided in the fuse box 1 2 3 Remove the front rack Remove the fuse box cover Remove the suspect fuse from the fuse panel If the fuse is blown install a new fuse with the same amperage rating Reinstall the fuse box cover Reinstall the front rack gt TO mor FEL 7175140 eU bal mmm V 101 MAINTENANCE Lights Poor lighting can result in reduced visibilitv when driving Headlight and taillight lenses become dirtv during normal operation Clean lights frequently and replace burned out lamps promptly Always make sure lights are adjusted properly for best visibility Headlight Lamp Replacement When servicing a halogen lamp avoid touching the lamp with bare fin gers Oil from your skin leaves a residue causing a
110. termine the cause or see your dealer 77 MAINTENANCE Periodic Maintenance Chart A WARNING Improperly performing the procedures marked with a lil could result in component failure and cause an accident which may result in serious injury or death Always have an authorized Polaris dealer perform these services Maintenance Chart Key P Perform these operations more often for vehicles subjected to severe use E Emission related service Failure to conduct this maintenance will not void the emissions warranty but may affect emissions Wi Have an authorized Polaris dealer perform these services Perform all services at whichever maintenance interval is reached first Item Maintenance Interval Remarks whichever comes first Hours Calendar Miles Km Steering Pre Ride Make adjustments as needed See Pre Ride Front suspension Pre Ride Checklist on page 54 Rear suspension Pre Ride Tires Pre Ride Brake fluid level Pre Ride Brake lever travel Pre Ride Brake system Pre Ride Passenger seat Pre Ride lock out Wheels fasteners Pre Ride Frame fasteners Pre Ride Engine oil level Pre Ride gt Air filter pre filter Daily Inspect clean often replace E as needed gt Air box sediment Daily Drain deposits when visible tube Coolant Daily Check level daily change coolant every 2 years gt ADC fluid Dailv Check level dailv add as
111. tery hold down strap 4 Onconventional batteries remove the battery vent tube 5 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 113 MAINTENANCE Batterv Batterv Installation Using a new batterv that has not been fullv charged can damage the bat terv and result in a shorter life It can also hinder vehicle performance Follow the batterv charging instructions on page 116 before installing the batterv 1 Ensure that the battery is fully charged 2 Place the battery in the battery holder 3 With conventional batteries install the battery vent tube sealed bat teries do not have a vent tube The vent tube must be free of obstructions and securely installed Route the tube away from the frame and vehicle body to prevent contact with electrolyte WARNING Battery gases could accumulate in an improperly installed vent tube and cause an explosion resulting in serious injury or death Always ensure that the vent tube is free of obstructions and is securely installed as recommended 4 Onconventional batteries coat the terminals with dielectric grease or petroleum jelly 5 Secure the battery hold down strap 6 Connect and tighten the red positive cable first Connect and tighten the black negative
112. the auxiliary brake system See page 34 95 MAINTENANCE Toe Alignment Use the following procedure to check the toe alignment of the vehicle The recommended toe alignment is 0 to 1 8 0 3 mm WARNING Severe injury or death can result from improper toe alignment and adjustment Do not attempt to adjust tie rod alignment All tie rod adjustments should be performed by an authorized Polaris dealer 1 Position the vehicle on a level surface p 2 Place the handlebars in a Stand straight ahead position 3 Tie a length of string String between two stands as shown in the illustration Position the stands so that the string is flush j with the side of the rear l tire If available you may use a long straight edge instead of string 2 j 4 Measure the distance from the string to the 1 Dem rim at the front 1 and rear 2 of the front rim O The rear measurement should be 1 5 mm more than the front measurement on each side of the vehicle to obtain the recommended 0 to 1 8 0 3 mm toe out alignment 5 Repeat the measurement procedure on the other side of the vehicle 6 Ifyou discover improper alignment see your Polaris dealer for ser vice 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 96 MAINTENANCE Seat Removal 1 Remove
113. the light assem bly Turn the lamp counterclockwise to remove it Apply dielectric grease to the socket and install the new lamp AN Reinstall the harness connector Test the light for proper operation Reinstall the taillight assembly C 10 Reinstall the two screws 105 MAINTENANCE Spark Plugs Spark Plug Recommendations Refer to the specifications section beginning on page 134 for the recom mended spark plug tvpe and gap for vour vehicle Torque spark plugs to specification NOTICE Using non recommended spark plugs can result in serious engine damage Alwavs use Polaris recommended spark plugs Plug Condition Torque Specification New Spark Plug 9 11 ft Ibs 12 15 Nm Previously Installed Spark Plug 17 20 ft Ibs 23 27 Nm Spark Plug Inspection Spark plug condition is indicative of engine operation Check the spark plug firing end condition after the engine has been warmed up and the vehicle has been driven at higher speeds Immediately check the spark plug for correct color See page 107 CAUTION A hot exhaust system and engine can cause burns Wear protective gloves when removing a spark plug for inspection 1 Rotate the spark plug cap 1 4 turn and pull it off the spark plug 2 Using the special wrench provided in the tool pouch rotate the spark plug counterclockwise to remove it 3 Reverse the procedure for spark plug installation Torque to specifi cation 106 MAINTEN
114. tion Always follow all inspection and maintenance procedures and schedules described in the owner s manual 11 SAFETV Safetv Warnings Protective Apparel Riding in this vehicle without wearing an approved helmet and protective evewear increases the risk of a serious injuries in the event of an accident Operator and passenger must alwavs wear an approved helmet that fits properlv and eve protection goggles or face shield Carrving a Passenger Do not carrv a passenger until vou have at least two hours of driving experience with this vehicle Carrving More Than One Passenger Carrying more than one passenger greatly reduces the operator s ability to balance and control the ATV which may result in an accident or overturn Never carry more than one passenger on this 2 up ATV Using Alcohol or Drugs Operating the ATV after consuming alcohol or drugs could adversely affect operator judgment reaction time balance and perception Never consume alcohol or drugs before or while operating an ATV 12 SAFETV Safetv Warnings Carrving a Passenger in the Cargo Box A passenger riding in the cargo box could fall from the vehicle unexpectediv or mav contact moving components both of which can result in severe injurv or death Never allow a passenger to ride in the cargo box Operating on Pavement Operating an ATV on paved surfaces including sidewalks paths parking lots and drivewavs mav a
115. urally modified neglected improperly maintained used for rac ing or used for purposes other than for which it was manufactured or for any damages which occur during trailer transit or as a result of unauthorized service or the use of unauthorized parts In addition this warranty does not cover physical damage to paint or finish stress cracks tearing or puncturing of upholstery material corrosion or defects in parts components or the ATV due to fire explosions or any other cause beyond Polaris control Warranty does not apply to 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 Wheels and tires Finished and unfinished surfaces Suspension components Carburetor Throttle body components Brake components Engine components Seat components Drive belts Clutches and components Hydraulic components Steering components Circuit breakers Fuses Batteries Electronic components Light bulbs Sealed beam lamps Warranty applies to the product only and does not allow for coverage of personal loss Some items are considered consumable meaning they are considered part of normal maintenance or part of completing an effective repair The following items are excluded from warranty coverage in the event of a warranty claim Spark Plugs Lubricants such as oil grease etc
116. ust replace as needed Cooling system 50 H 6M 1000 1600 Inspect coolant strength seasonally pressure test system yearly gt Radiator 50 H 6M 1000 1600 Inspect clean external surfaces gt Cooling hoses 50 H 6M 1000 1600 Inspect for leaks gt Engine oil change 100 H 6M 1000 1600 Perform a break in oil change at one month P Oil filter change 100 H 6M 1000 1600 Replace with oil change gt Demand drive fluid 100 H 12M 1000 1600 Change fluid gt Rear gearcase oil 100 H 12M 1000 1600 Change fluid gt Transmission oil 100 H 12M 1000 1600 Change fluid 79 MAINTENANCE Periodic Maintenance Chart Item Maintenance Interval Remarks whichever comes first Hours Calendar Miles Km Fuel system 100 H 12M 1000 1600 Check for leaks at tank cap lines filter pump replace lines every two years gt Engine mounts 100 H 12M 1000 1600 Inspect Exhaust muffler 100 H 12M 1000 1600 Inspect pipe E Spark plug 100 H 12M 1000 1600 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 W Clutches drive 100 H 12M 1000 1600 Inspect clean replace worn and driven parts E Front wheel 100 H 12M 1000 1600 Inspect replace as needed bearings E Brake fluid 200H 24M 2000 3200 Change every two years
117. vehicle to lean sharply to one side Shift body weight uphill A passenger should also shift body weight uphill Apply the brakes slightly to aid in slowing Applying the brakes too firmly may cause the rear wheels to lock which could result in loss of control 65 OPERATION Turning Around on a Hill K Turn If the vehicle stalls while climbing a hill never back it down the hill Use the K turn to turn around 66 OPERATION Turning Around on a Hill K Turn l 2 Stop and lock the parking brake while keeping body weight uphill Never operate in TURF mode while operating on a hill or other irregular terrain Always move the 4X4 switch to ADC 4X4 before ascending or descending a hill See page 38 Leave the transmission in forward and shut off the engine If a passenger is on board ask the passenger to dismount first then the operator may dismount Dismount on the uphill side of the vehi cle or on the left if the vehicle is pointing straight uphill 4 passen ger should not remount until the vehicle returns to firm level ground Staying uphill of the vehicle turn the handlebars full left While holding the brake lever release the parking brake lock and slowly allow the vehicle to roll around to your right until it s point ing across the hill or slightly downward Lock the parking brake Remount the vehicle from the uphill side keeping body weight uphill Start the engine with the transmission still i
118. warranty on your Polaris ATV is terminated if any equipment has been added to the vehicle or if any modifications have been made to the vehicle that increase its speed or power The addition of certain accessories including but not limited to mow ers blades tires sprayers or large racks may change the handling char acteristics of the vehicle Use only Polaris approved accessories and familiarize yourself with their function and effect on the vehicle SAFETV Safetv Warnings A WARNING Failure to operate the ATV properly can result in a collision loss of control accident or overturn which may result in serious injury or death Heed all safety warnings outlined in this section of the owner s manual See the OPERATION section of the owner s manual for proper operating procedures Operating Without Instruction Operating this ATV without proper instruction increases the risk of an accident The operator must understand how to operate the ATV properly in different situations and on different types of terrain Beginning and inexperienced operators should complete the recommended safety training before operating this vehicle See page 7 Never permit a guest to operate the ATV unless the guest has read this manual and all product labels and has completed a certified safety training course Age Restrictions This vehicle is an ADULT VEHICLE ONLY Operation is prohibited for anyone under 16 years of age Never allow anyone un
119. when cargo is high When handling off centered loads that cannot be centered secure the load and operate with extra caution SECURE ALL LOADS BEFORE OPERATING Unsecured loads may shift and create unstable operating conditions which could result in loss of control of the vehicle Always be sure that the cargo bed is lowered and latched before moving the vehicle USE EXTREME CAUTION when operating with loads extending beyond the rack or cargo bed Stability and maneuverability may be adversely affected causing the machine to overturn BALANCE LOADS proportionally between the front rack and cargo bed but do not exceed the stated load capacity Carrying a load on only the front rack or cargo bed may cause an imbalanced condition and increases the possibility of vehicle overturn USE EXTREME CAUTION when applying brakes with a loaded vehicle Avoid terrain or situations that may require backing downhill Always attach the tow load to the hitch point DO NOT TRAVEL FASTER THAN THE RECOMMENDED SPEEDS The vehicle should never exceed 10 mph 16 kph while towing a load on a level surface Vehicle speed should never exceed 5 mph 8 kph when towing loads in rough terrain while cornering or while ascending or descending a hill DO NOT BLOCK THE FRONT HEADLIGHT BEAM when carrying loads on the front rack 72 OPERATION Hauling Cargo Never exceed the weight capacities specified for vour ATV on warning labels and in the specifications sect
120. when carrying a passenger dismount passenger when conditions require make sure passenger reads and understands this label and passenger safety label LOCATE AND READ OPERATOR S MANUAL FOLLOW ALL INSTRUCTIONS AND WARNINGS 7175844 22 SAFETV Safetv Labels and Locations General Warning Passenger Safetv Discretionarv Warning Age 16 Warning Reverse Override Warning 4X4 Caution Age 16 Warning WARNING Operating this ATV if vou are under the age of 16 increases the chances of severe injurv or death to both operator and passenger NEVER operate this vehicle if vou are under age 16 7175375 Reverse Override Warning AWD Caution WARNING Improper use of override button can lead to loss of control resulting in severe injurv or death Do not activate override while throttle is engaged Alwavs applv throttle graduallv while in reverse CAUTION Do not push switch to engage 4x4 AWD if the rear wheels are spinning This mav cause severe drive shaft and clutch damage 7175512 23 SAFETV Safetv Labels and Locations Passenger Safety Discretionary Warning WARNING PASSENGER SAFETY To reduce the risk of SEVERE INJURY or DEATH NEVER CARRY MORE THAN ONE PASSENGER NEVER RIDE AFTER USING DRUGS OR ALCOHOL NEVER carry a passenger too small to firmly plant feet on footrests and securely grasp hand holds THE PASSENGER MUST ALWAYS use an approved helmet and protective gear securely grasp hand holds an
121. y engine power Never apply the rear brake while rolling backwards Apply the single lever brake gradually When fully stopped apply the foot brake as well and then lock the parking brake Dismount on the uphill side of the vehicle or on the left if the vehicle is pointing straight uphill Have a passenger dismount first then the operator may dismount Turn the ATV around and remount following the procedure described in the owner s manual See page 66 Operating on Steep Hills Operating on excessively steep hills could cause an overturn Never operate on hills too steep for the ATV or for your abilities Never operate the ATV on hills steeper than 15 degrees 16 SAFETV Safetv Warnings Operating on Slipperv Terrain Failure to use extra caution when operating on excessivelv rough slipperv or loose terrain could cause loss of traction loss of control accident or overturn Do not operate on excessively rough slippery or loose terrain until you ve learned and practiced the skills necessary to control the ATV on such terrain Always use extra caution on rough slippery or loose terrain Operating in Unfamiliar Terrain Failure to use extra caution when operating on unfamiliar terrain could result in an accident or overturn Unfamiliar terrain may contain hidden rocks bumps or holes that could cause loss of control or overturn Travel slowly and use extra caution when operatin

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