Polaris 2010 Sportsman X2 550 EFI Owner'S Manual Download Page 124 | Manualshive

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122

MAINTENANCE

Spark Plugs

Spark Plug Recommendations

Refer to the specifications section beginning on page 148 for the
recommended spark plug type and gap for your vehicle. Torque spark
plugs to specification.

NOTICE:

Using non-recommended spark plugs can result in serious engine
damage. Always use POLARIS-recommended spark plugs.

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 123.

CAUTION!

A hot exhaust system and engine can cause burns. Wear

protective gloves when removing a spark plug for inspection.

1. Rotate the spark plug cap 1/4 turn and pull it off the spark plug.

2. Using the special wrench provided in the tool pouch, rotate the

spark plug counter-clockwise to remove it.

3. Reverse the procedure for spark plug installation. Torque to

specification.

Plug Condition

Torque Specification

New Spark Plug

9-11 ft. lbs.

(12-15 Nm)

Previously Installed

Spark Plug

17-20 ft. lbs.

(23-27 Nm)

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Summary of Contents for 2010 Sportsman X2 550 EFI

Page 1: ...this manual carefully It contains important safety information This is an adult vehicle only Operation is prohibited for those under 16 years of age Owner s Manual for Maintenance and Safety Sportsma...

Page 2: ...r 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 WARNING The engine exhaust from this product contains chemicals known to...

Page 3: ...recreational vehicles manufactured in the world today Many years of experience have gone into the engineering design and development of your POLARIS vehicle making it the finest machine we ve ever pr...

Page 4: ...tween the actual vehicle and the information presented in this publication Depictions and or procedures in this publication are intended for reference use only No liability can be accepted for omissio...

Page 5: ...ntroduction 4 Safety 7 Features and Controls 28 Operation 55 Winch Guide 78 Emission Control Systems 90 Maintenance 91 Troubleshooting 143 POLARIS Products 147 Specifications 148 Warranty 150 Maintena...

Page 6: ...tuation that if not avoided will result in death or serious injury WARNING A WARNING indicates a hazardous situation that if not avoided could result in death or serious injury CAUTION A CAUTION indic...

Page 7: ...eration 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 trainin...

Page 8: ...ting keys The ignition switch must be replaced if all keys are lost The manufacturer s label is located on the front right side of the vehicle behind the radiator Vehicle Model Number ________________...

Page 9: ...iderCoursesm 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 enforceme...

Page 10: ...r on approved models should wear a helmet 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...

Page 11: ...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 A...

Page 12: ...nt 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 gu...

Page 13: ...ange 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 ex...

Page 14: ...carry a passenger until you have at least two hours of driving experience with this vehicle Carrying More Than One Passenger Carrying more than one passenger greatly reduces the operator s ability to...

Page 15: ...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 st...

Page 16: ...should always be seated in the passenger seat with both feet on the footrests and both hands on the passenger grab handles at all times The passenger should never hold on to the operator Turning Impr...

Page 17: ...manual See page 67 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 irr...

Page 18: ...then the operator may dismount Turn the ATV around and remount following the procedure described in the owner s manual See page 68 If the ATV begins rolling backwards Keep operator and passenger body...

Page 19: ...n 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...

Page 20: ...stacles 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 cautio...

Page 21: ...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 capacit...

Page 22: ...urrents may result in uneven ice thickness Always check with local authorities and residents to confirm ice conditions and thickness over your entire route ATV operators assume all risk associated wit...

Page 23: ...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 Systems Exhaust system components are very hot...

Page 24: ...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...

Page 25: ...arning AWD Caution WARNING Improper use of override button can lead to loss of control resulting in severe injury or death Do not activate override while throttle is engaged Always apply throttle grad...

Page 26: ...S use an approved helmet and protective gear securely grasp hand holds and plant feet firmly on footrests while seated in the passenger seat tell operator to slow down or stop if uncomfortable get off...

Page 27: ...verloading can cause loss of control Loss of control can result in severe injury or death Cold tire pressure Front 7 0 psi 48 3 kPa Rear 7 0 psi 48 3 kPa Maximum weight capacity 735 lbs 333 kg Lug nut...

Page 28: ...P Moving parts hazard under belt clutch guard To prevent serious injury do not operate vehicle with guard removed Do not modify engine or clutch Doing so can cause part failure possible imbalance and...

Page 29: ...ns Box Warning WARNING Remove flammable material containers from box before filling WARNING Passengers can be thrown off This can cause serious injury or death Never carry passengers in cargo box Maxi...

Page 30: ...as a MODE button when held down for approximately one half second See the instrument cluster information beginning on page 44 Tip The override button will not function as a MODE button if the transmis...

Page 31: ...mode See pages 38 39 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 of...

Page 32: ...o the throttle release switch could result in failure to perform as designed which could result in an accident Do not attempt to modify the throttle control system or replace it with any after market...

Page 33: ...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 a...

Page 34: ...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 mas...

Page 35: ...unlocked position WARNING Operating the ATV while the parking brake is engaged could result in an accident or fire Always check to be sure the parking brake is disengaged before operating The parking...

Page 36: ...loss of control and serious injury or death The auxiliary brake system is intended to be used as a backup for the main brake system Should the main system fail use the auxiliary foot brake Since this...

Page 37: ...iary brake system The reservoir is located under the front storage box See page 43 Maintain the fluid level between the maximum and minimum marks Use DOT 4 brake fluid only NOTICE Do not use ADC fluid...

Page 38: ...le 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 whe...

Page 39: ...o allow for the normal expansion of fuel Do not overfill Do not fill the tank neck Extreme Use 30 AH Battery If your factory installed 18 AH battery cannot maintain a charge because of operation in ex...

Page 40: ...ding a hill See page 40 4X4 Mode When the switch is on 4X4 the ATV is in 4X4 and the 4X4 indicator light in the instrument cluster will be on When in 4X4 the demand drive unit will automatically engag...

Page 41: ...ol 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 th...

Page 42: ...following 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 g...

Page 43: ...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 latch...

Page 44: ...ns 6 Lower the operator backrest to create the passenger seat Two retaining pins under the seat should fit into the two grommets on the seat base 7 Test the passenger seat lock out by attempting to re...

Page 45: ...he rack illustration Position the front edge in the tabs then push the box downward and secure the latches Access the following components in the front compartment Radiator cap Brake fluid reservoir A...

Page 46: ...he 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...

Page 47: ...tomatically reduce engine power EPS Warning This indicator illuminates when the key is turned to the ON position and goes off when the engine is started If the light remains on after starting the engi...

Page 48: ...cluster fails to illuminate a battery over voltage may have occurred and the instrument cluster may have shut off to protect the electronic speedometer If this occurs take the ATV to your POLARIS deal...

Page 49: ...Display This area displays odometer trip meter engine hour meter engine speed and programmable service hour interval 4 Active Descent Control Display This icon displays when ADC is active See page 40...

Page 50: ...d or metric units of measurement Tip To exit the set up mode at any time wait 10 seconds The display automatically exits and returns to the odometer display 1 Turn the key to the OFF position 2 Place...

Page 51: ...elease the button 5 Repeat steps 3 4 twice to set the 10 minute and 1 minute segments After completing the 1 minute segment step 4 will save the new settings and exit the clock mode 6 Turn the key to...

Page 52: ...button 3 When the service hours flash press and release the MODE button to advance the hours to the desired setting including OFF Press and hold the MODE button to set the new service hour interval Di...

Page 53: ...e display Please see your Polaris dealer for all major repairs 1 If the error codes are not displayed use the MODE button to toggle until Ck ENG displays on the main line of the display 2 Press and ho...

Page 54: ...e 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...

Page 55: ...ltage 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 O...

Page 56: ...round 520225 4 T1 and T2 Shorted to Bus 520225 3 T1 Shorted to Ground T2 Shorted to Bus 520225 16 T2 Shorted to Ground T1 Shorted to Bus 520225 17 T1 and T2 are Shorted 520225 2 Steering Position Sens...

Page 57: ...xtreme caution whenever handling gasoline 2 Check the engine oil level on the dipstick See page 96 Add oil if necessary to maintain the level between the safe and add marks 3 Drive slowly at first Sel...

Page 58: ...ion Tires Inspect condition and pressure 114 Wheels fasteners Inspect ensure fastener tightness 114 115 Frame nuts bolts fasteners Inspect ensure tightness Fuel and oil Ensure proper levels 37 96 Cool...

Page 59: ...a manner appropriate for your skills your passenger s skills and operating conditions Never operate at excessive speeds Never attempt wheelies jumps or other stunts Never remove your hands from the ha...

Page 60: ...icle 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 alwa...

Page 61: ...If the engine does not start return the key to the OFF position and wait five seconds before attempting to start again Activate the starter for another five seconds if necessary Repeat this procedure...

Page 62: ...side 6 Sit upright with both feet on the footrests and both hands on the handlebars 7 Start the engine and allow it to warm up 8 Shift the transmission into gear 9 Check your surroundings and determin...

Page 63: ...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 tr...

Page 64: ...ways make sure the passenger seat lock out is functioning properly before carrying a passenger 6 Lock the parking brake 7 Mount the vehicle from the left side After the operator is seated the passenge...

Page 65: ...r 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...

Page 66: ...traction NOTICE Severe damage to drive train may occur if the 4X4 is engaged while the wheels are spinning Allow the rear wheels to stop spinning before engaging 4X4 or engage 4X4 before wheels begin...

Page 67: ...imum 4 Always check the terrain carefully before ascending any hill 5 Never climb hills with excessively slippery or loose surfaces 6 Keep both feet on the footrests 7 Shift body weight uphill A passe...

Page 68: ...ow these precautions 1 Slow down 2 Avoid crossing the side of a steep hill 3 Do not cross a hillside with a passenger on board Ask the passenger to dismount and walk across the hillside before remount...

Page 69: ...descend a hill with the transmission in forward gear Do not descend a hill with the transmission in neutral 4 Slow down Never travel down a hill at high speed 5 Drive straight downhill Avoid traveling...

Page 70: ...68 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 8 ft 2 4 m...

Page 71: ...the vehicle or on the left if the vehicle is pointing straight uphill A passenger should not remount until the vehicle returns to firm level ground 5 Staying uphill of the vehicle turn the handlebars...

Page 72: ...id 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 y...

Page 73: ...constantly alert for hazards such as logs rocks and low hanging branches 3 Travel slowly and use extra caution when operating on unfamiliar terrain Not all obstacles are immediately visible 4 Never at...

Page 74: ...turning at sharp angles 6 Never open the throttle suddenly 7 Do not use the override switch unless additional wheel speed is required for vehicle movement Use the override with caution as rearward veh...

Page 75: ...an Incline Avoid parking on an incline if possible If it s unavoidable follow these precautions 1 Stop the engine 2 Place the transmission in PARK 3 Lock the parking brake 4 Always block the rear whee...

Page 76: ...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 loa...

Page 77: ...carrying a passenger 6 NEVER exceed 10 MPH 16 km h when rear cargo loads are above 200 lbs 91 kg and or front cargo loads are above 100 lbs 45 kg 7 Always load the cargo box with the load as far forw...

Page 78: ...ed the maximum weight capacity of the vehicle NOTICE Using an improper hitch or exceeding the maximum tongue weight capacity can result in serious damage to the vehicle and will void your ATV warranty...

Page 79: ...ion the weight as far forward and as low as possible 6 Pull the cargo box release strap upward 7 Lift the front of the cargo box and dump the cargo 8 Lower the cargo box and make sure the release latc...

Page 80: ...and heavy gloves when operating the winch 5 Always keep body hair clothing and jewelry clear of the winch cable fairlead and hook when operating winch 6 Never attempt to jerk a load attached to the wi...

Page 81: ...eed and rewind the cable evenly before continuing the winch operation 13 Never winch up or down at sharp angles This can destabilize the winching vehicle and possibly cause it to move without warning...

Page 82: ...ays inspect your winch and winch cable before each use 23 Never winch the hook fully into the winch This can cause damage to winch components 24 Unplug the remote control from the vehicle when the win...

Page 83: ...strategy if it is not working Always remember that your winch is very powerful There are simply some situations that you and your winch will not be able to deal with Do not be afraid to ask others to...

Page 84: ...able at the first sign of damage to prevent SEVERE INJURY or DEATH in the event of failure For your safety always replace POLARIS winch parts including the cable with genuine POLARIS replacement parts...

Page 85: ...jacket tarp or other soft dense object A damper can absorb much of the energy released if a winch cable breaks when winching Even a tree limb can help as a damper if no other items are available to yo...

Page 86: ...frame following instructions in this manual D Re engage the clutch on the winch E Slowly winch in the slack in the winch cable F Select the proper vehicle gear to propel the stuck vehicle in the direc...

Page 87: ...is complete especially if winching at an angle it may be necessary to re distribute the winch cable across the winch drum You will need an assistant to perform this task A Release the clutch on the wi...

Page 88: ...cable has already been permanently and severely damaged Promptly discontinue use of a winch cable in this condition B A kinked winch cable made of wire rope that has been straightened out is shown at...

Page 89: ...in an attempt to move an object This is a dangerous practice It gener ates high winch cable loads that may exceed the strength of the cable Even a slowly moving vehicle can create large shock loads in...

Page 90: ...y never use elastic bungie cords for winching 5 Never use the winch to tie down a vehicle to a trailer or other transportation vehicle This type of use also causes shock loading that can cause damage...

Page 91: ...tivation of the winch 4 For your safety always replace POLARIS winch parts including the cable with genuine POLARIS replacement parts available at your authorized POLARIS dealer 5 Some winch models us...

Page 92: ...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 co...

Page 93: ...rm 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 u...

Page 94: ...D Have an authorized POLARIS dealer perform these services Item Maintenance Interval whichever comes first Remarks Hours Calendar Miles Km Steering Pre Ride Make adjustments as needed See Pre Ride Che...

Page 95: ...500 800 Inspect lubricate D Steering 50 H 6 M 500 800 Lubricate Front suspension 50 H 6 M 500 800 Lubricate Rear suspension 50 H 6 M 500 800 Lubricate D E Throttle Cable Throttle Release Switch 50 H 6...

Page 96: ...1600 Inspect D E Spark plug 100 H 12 M 1000 1600 Inspect replace as needed Wiring 100 H 12 M 1000 1600 Inspect for wear routing security apply dielectric grease to connectors subjected to water mud e...

Page 97: ...5W 50 4 Cycle Oil 2 qt 1 9 l 15 17 ft lbs 20 23 Nm Page 96 Transmission Oil AGL Gearcase Lubricant Transmission Fluid 37 oz 1100 ml 10 14 ft lbs 14 19 Nm 10 14 ft lbs 14 19 Nm Page 100 Demand Drive Fl...

Page 98: ...OLARIS oil is not used Always use 5W 50 oil Follow the manufacturer s recommendations for ambient temperature operation See page 147 for the part numbers of POLARIS products See the table on page 95 f...

Page 99: ...the oil dipstick and fill tube from the left side of the ATV Remove the dipstick Wipe it dry with a clean cloth 3 Reinstall and tighten the dipstick 4 Remove the dipstick and check the oil level 5 Add...

Page 100: ...tart the engine Allow it to warm up at idle for two to three minutes 3 Stop the engine 4 Clean the area around the drain plug 5 Place a drain pan under the crankcase 6 Remove the drain plug Allow the...

Page 101: ...s in good condition 12 Install the new filter and rotate it clockwise by hand until the filter gasket contacts the sealing surface then turn it an additional 1 2 turn 13 Remove the dipstick Add the pr...

Page 102: ...Maintain the oil level at the bottom of the fill plug hole The fill plug is located on the right side of the ATV behind the footwell The drain plug is located on the bottom left side of the gearcase...

Page 103: ...move the drain plug Allow the oil to drain completely 3 Clean and reinstall the drain plug Torque to specification 4 Remove the fill plug Add the proper amount of the recommended oil 5 Reinstall the f...

Page 104: ...Use Definition operation in ADC mode for prolonged periods constant ADC operation on hilly or mountainous terrain ADC is the primary mode of all wheel drive operation Use the recommended fluid Use of...

Page 105: ...3 Reinstall the fill plug Torque to specification Fluid Change 1 Position the vehicle on a level surface Remove the fill plug 2 Place a drain pan under the demand drive unit Remove the drain plug All...

Page 106: ...Maintain the fluid level between the minimum and maximum marks on the reservoir See page 147 for the part numbers of POLARIS products NOTICE Do not use brake fluid Brake fluid will damage rubber comp...

Page 107: ...eeder valves 6 Slowly loosen one of the bleeder valve 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 th...

Page 108: ...products The fill plug is located on the rear of the gearcase The drain plug is located on the bottom of the gearcase Maintain the fluid level at the bottom of the fill hole threads Do not overfill Oi...

Page 109: ...ug 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 7 Check for l...

Page 110: ...t is drawn back up from the bottle past the pressure cap and into the radiator Some coolant level drop on new vehicles is normal as the system is purging itself of trapped air Check the coolant level...

Page 111: ...e cap under the front storage compartment 1 View the fluid level in the bottle 2 If the level is low remove the front box 3 Remove the bottle cap and add coolant as needed Maintain the coolant level b...

Page 112: ...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 befor...

Page 113: ...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 ad...

Page 114: ...at the string is flush with the side of the rear tire If available you may use a long straight edge instead of string 4 Measure the distance from the string to the rim at the front 1 and rear 2 of the...

Page 115: ...of the seat near the opposite rear corner 4 Pull upward abruptly to disengage the under seat fasteners 5 Remove the seat Side Panel Footwell Removal 1 Remove the seat before removing a side panel 2 To...

Page 116: ...commended tire type size and pressure Tire Tread Depth Always replace tires when tread depth is worn to 1 8 3 mm or less Front Wheel Hub Tightening Front wheel bearing tightness and spindle nut retent...

Page 117: ...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 a...

Page 118: ...ove the filter 4 Remove the fabric type pre filter from the main filter Wash the pre filter in soapy water then rinse and let dry 5 Reinstall the pre filter over the main filter Install a new main fil...

Page 119: ...orrect any short circuits that may have caused the blown fuse then replace the fuse Spare fuses are provided in the fuse box 1 Remove the front box 2 Remove the fuse box cover 3 Remove the suspect fus...

Page 120: ...in leaves a residue causing a hot spot that will shorten the life of the lamp If fingers do touch a lamp clean it with denatured alcohol 1 Remove the five 5 headlight pod screws 2 Lift the pod cover a...

Page 121: ...of the headlight and make a mark on the wall at the same height 3 Start the engine Turn the headlight switch to high beam 4 Observe the headlight aim on the wall The most intense part of the headligh...

Page 122: ...Remove the five 5 headlight pod screws 2 Lift the pod cover and disconnect the speedometer harnesses from the speedometer 3 Unplug the headlamp from the wiring harness 4 Use a small screwdriver to re...

Page 123: ...ure the headlamp Taillight Brakelight Lamp Replacement 1 Open the tailgate 2 Remove the two screws near the tailgate latch 3 Grasp the entire taillight assembly and pull it away from the vehicle 4 Rem...

Page 124: ...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 123 CAUTION A hot exhaust system and engine can cause...

Page 125: ...ine and the service The tip should not be flaky and white A white insulator tip indicates overheating caused by use of an improper spark plug or incorrect fuel Wet Fouled Spark Plug The wet fouled ins...

Page 126: ...is present dry the air box and replace the filter with a new filter 3 Remove the spark plugs 4 Turn the engine over several times using the electric start 5 Dry the spark plugs Reinstall the plugs or...

Page 127: ...n from the exhaust pipe muffler 1 Remove the arrester clean out plug from the bottom of the muffler 2 Place the transmission in PARK 3 Start the engine 4 Quickly squeeze and release the throttle lever...

Page 128: ...peeds 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 respons...

Page 129: ...ue to the system s dependence on engine speed For example when operating at a ground speed of 3 MPH 5 km h in low range the engine speed would be around 3000 RPM This is well above the engagement spee...

Page 130: ...in plug Allow the water to drain completely Reinstall the drain plug 3 Start the engine Place the transmission in PARK 4 Apply varying throttle for 10 15 seconds to expel the moisture and air dry the...

Page 131: ...of the battery could result in electrolyte leakage which would shorten the life of the battery considerably Always keep battery terminals and connections free of corrosion If cleaning is necessary re...

Page 132: ...ase see your POLARIS dealer to purchase a 30 AH battery Before installing the 30 AH battery remove the plastic spacer at the bottom of the battery compartment Save the spacer for future use 1 Ensure t...

Page 133: ...needed to maintain a full charge Tip Power plug leads may need to be bent down so that the battery cover can be installed POLARIS recommends maintaining battery charge by using a POLARIS Battery Tende...

Page 134: ...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 batter...

Page 135: ...ps specified on top of battery 100 12 8 13 0 volts None check at 3 mos from date of manufacture None required 75 100 12 5 12 8 volts May need slight charge if no charge given check in 3 months 3 6 hou...

Page 136: ...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 adjuster Squeeze the end of the rubber boot and slide it back far e...

Page 137: ...ase see your POLARIS dealer for service 7 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...

Page 138: ...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...

Page 139: ...n adjustable Front and Rear Springs The front and rear shock absorber springs are adjusted by rotating the adjuster either clockwise or counter clockwise to increase or decrease spring tension Accesso...

Page 140: ...e the frame of the ATV to the transporting unit securely with suitable straps or rope Do not attach tie straps to the front A arm bolt pockets 7 Remove the key to prevent loss during transporting Acce...

Page 141: ...to contact the vehicle The best and safest way to clean your POLARIS vehicle is with a garden hose and a pail of mild soap and water 1 Use a professional type washing cloth cleaning the upper body fi...

Page 142: ...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 furni...

Page 143: ...t beginning on page 91 Demand drive unit front gearcase ADC fluid ADC models change every two years Rear gearcase if equipped Transmission Brake fluid change every two years and any time the fluid loo...

Page 144: ...l 5 If POLARIS fuel system additive is not used the fuel tank fuel lines and injectors should be completely drained of gasoline Air Filter Air Box 1 Inspect and clean or replace the pre cleaner and ai...

Page 145: ...ift 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...

Page 146: ...k plug s Inspect plugs and replace if neces sary 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 Rechar...

Page 147: ...inked 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...

Page 148: ...oose 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...

Page 149: ...2877922 Demand Drive Plus Fluid qt 95 l 2877923 Demand Drive Plus Fluid gal 3 8 l 2870465 Pump for Gallon 3 8 l Jug Coolant 2871323 Polaris Antifreeze 60 40 Premix gal 3 8 l 2871534 Polaris Antifreez...

Page 150: ...ng 1500 lbs 680 kg on level ground Unbraked Trailer Towing Capacity 1995 lbs 905 kg Overall Length 93 25 in 237 cm Overall Width 47 6 in 121 cm Overall Height 49 5 in 125 7 cm Wheelbase 57 in 145 cm G...

Page 151: ...Control Hydraulic Disc All Wheel Brake Auxiliary Foot Activated Hydraulic Disc Rear Wheel Brake Parking Hydraulic lock all wheel Headlight 1 Single Beam on Headlight Pod 50 watt 2 Single Beam on Bumpe...

Page 152: ...the original registration and received the customer copy please contact your dealer immediately NO WARRANTY COVERAGE WILL BE ALLOWED UNLESS YOUR VEHICLE IS REGISTERED WITH POLARIS Initial dealer prepa...

Page 153: ...ngine oil 2 Damage or failure resulting from the use of non recommended lubricants or fluids is not covered by this warranty This warranty provides no coverage for personal loss or expense including m...

Page 154: ...THIS EXCLUSION OF CONSEQUENTAL INCIDENTAL AND SPECIAL DAMAGES IS INDEPENDENT FROM AND SHALL SURVIVE ANY FINDING THAT THE EXCLUSIVE REMEDY FAILED OF ITS ESSENTIAL PURPOSE THE IMPLIED WARRANTY OF FITNE...

Page 155: ...he selling dealer s authorized location as proof of residence Upon residence verification the servicing dealer will be authorized to perform the warranty repair If you move If you move to another coun...

Page 156: ...tside of the country where it was purchased and you have not followed the procedure set above your product will no longer be eligible for warranty or service bulletin coverage of any kind other than s...

Page 157: ...ar months from the date of purchase whichever comes first This EPA emissions warranty period is extended for at least as long as the standard factory warranty that Polaris provides on the vehicle as a...

Page 158: ...ERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE ARE LIMITED IN DURATION TO THE WARRANTY PERIOD DESCRIBED HEREIN POLARIS DISCLAIMS ALL EXPRESS WARRANTIES NOT STATED IN THIS WARRANTY Some states do...

Page 159: ...upplied by an aftermarket parts manufacturer reduces the effectiveness of the vehicle s emission controls Tampering with emission controls is prohibited by federal law California Residents Certain POL...

Page 160: ...section of your manual to your dealer each time your vehicle is serviced This will provide you and future owners with an accurate log of maintenance and services performed DATE MILES KM OR HOURS TECHN...

Page 161: ...159 MAINTENANCE LOG DATE MILES KM OR HOURS TECHNICIAN SERVICE PERFORMED COMMENTS...

Page 162: ...er Operation 59 C Consumer Product Safety 7 Coolant Bottle 109 Coolant Radiator 110 Cooling System 108 110 Crankcase Emission Control System 90 D Demand Drive Fluid 102 103 Diagnostic Codes 53 54 Dise...

Page 163: ...52 54 Gauge Digital Analog 44 51 Gear Selector 36 Gearcase Oil Rear 106 107 Gloves 9 H Hand Brake 111 Handlebar Adjustment 136 Hauling Cargo 74 77 Headlight Housing Replacement 120 Headlight Lamp Rep...

Page 164: ...n Center 46 51 Riding Area 58 Riding Gear 8 9 S Safe Operation Practices 57 Safety Labels 22 27 Safety Training 7 Safety Warnings 10 21 Safety Winch Maintenance 89 Seat Removal 113 Severe Use 91 Shock...

Page 165: ...8 Turning Around on a Hill 68 69 Turning the Vehicle 61 V Vehicle Identification Numbers 6 Vehicle Immersion 124 VIN 6 W Warning Symbols 4 Washing the Vehicle 139 140 Wheel Installation 115 Wheel Nut...

Page 166: ...unless passenger seat is securely in place THE OPERATOR MUST ALWAYS use proper riding techniques to avoid vehicle overturns on hills and rough terrain and in turns avoid paved surfaces pavement may s...

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