Polaris BRUTUS Owner'S Manual Download Page 37 | Manualshive

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36

OPERATION

Fuel Recommendations

NOTICE: For the best engine performance, to prevent engine

damage and to comply with EPA/CARB warranty
requirements, use ONLY the recommended diesel fuels.
Use only CLEAN diesel fuel.

POLARIS recommends the following diesel fuels for use in
this vehicle:
• Low Sulfur
• Ultra Low Sulfur #2
• #1 Diesel Fuel containing no more than 5% bio-diesel (see

See page 39 for cold weather fuel blend recommendations. For
more information about recommended diesel fuels and the
consequences of using bio-diesel fuel exceeding 5% bio-die-
sel, see Additional Technical Fuel Requirements below.

Diesel fuel should comply with the following world-wide
specifications.

Additional Technical Fuel Requirements

• The fuel cetane number should be equal to 45 or higher.
• The sulfur content must not exceed 0.5% by volume. Less

than 0.5% is preferred. Especially in the U.S.A. and Canada,
Low Sulfur (300 to 500 ppm (mg/kg) or Ultra Low Sulfur
fuel should be used.

• Bio-Diesel fuels: see pages 37-38.
• NEVER mix kerosene, used engine oil or residual fuels with

diesel fuel.

• Water and sediment in the fuel should not exceed 0.05% by

volume.

• Keep the fuel tank and fuel-handling equipment clean at all

times.

• Poor quality fuel can reduce engine performance and/or

cause engine damage.

• Fuel additives are not recommended. Some fuel additives

may cause poor engine performance.

• Ash content must not exceed 0.01% by volume.
• Carbon residue content must not exceed 0.35% by volume.

Less than 0.1% is preferred.

• Total aromatics content should not exceed 35% by volume.

Less than 30% is preferred.

• PAH (polycyclic aromatic hydrocarbons) content should be

below 10% by volume.

• Metal content of Na, Mg, Si and Al should be equal to or

lower than 1 mass ppm (test analysis method JPI-5S-44-95).

• Lubricity: Wear mark of WS1.4 should be Max. 0.018 in.

(460µm) at HFRR test.

Diesel Fuel Specification

Location

ASTM D975

No. 1D S15, S500

No. 2D S15, S500

USA

EN590:96

European Union

ISO 8217 DMX

International

BS 2869-A1 or A2

United Kingdom

JIS K2204 Grade No. 2

Japan

KSM-2610

Korea

GB252

China

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Summary of Contents for BRUTUS

Page 1: ...PMS 419 BRUTUS BRUTUS HD BRUTUS HDPTO Owner s Manual for Maintenance and Safety ...

Page 2: ...ne 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 Ser vice Manual and should be performed only by a Factory Certified Master Service Dealer MSD Technician Your POLARIS dealer knows ...

Page 3: ...ay result between the actual vehicle and the information presented in this publication Depictions and or procedures in this publication are intended for reference use only No liability can be accepted for omissions or inaccuracies Any reprinting or reuse of the depictions and or procedures contained within whether whole or in part is expressly prohibited The original instructions for this vehicle ...

Page 4: ...on 4 Safety 6 Features And Controls 18 Operation 34 Attachment Arm 70 PTO System 74 Emission Control Systems 76 Maintenance 77 Specifications 125 Polaris Products 128 Troubleshooting 130 Warranties 131 Maintenance Log 136 Index 137 ...

Page 5: ...difficult terrain Never engage in stunt driving and avoid excessive speeds and sharp turns Riding and alcohol drugs don t mix Check local laws before riding trails The BRUTUS is an off road vehicle Familiarize yourself with all laws and regulations concerning the operation of this vehi cle in your area The following signal words and symbols appear throughout this manual and on your vehicle Your sa...

Page 6: ...perceived noise and hand arm and whole body vibration levels of this machinery is measured per prEN 15997 The operating conditions of the machinery during testing The vehicles were in like new condition The environment was controlled as indicated by the test procedure s The uncertainty of vibration exposure measurement is depen dent on many factors including Instrument and calibration uncertainty ...

Page 7: ...the instructions of the labels on the vehicle If any label becomes illegible or comes off contact 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 PTO Warning If Equipped Discretionary Warning Age 16 Warning Shift Caution To Start Engine To Leave vehicle Attachment Arm Warning If Equipped Seat Switc...

Page 8: ...ssing 7179343 Discretionary Warning WARNING Improper vehicle use can result in Serious Injury or Death NEVER Operate At speeds too fast for your skills or the conditions After or while using Alcohol or Drugs On hills steeper than 15 degrees 15 On public roads a collision can occur with a another vehicle With passengers under age twelve or who cannot comfortably reach the floor and hand holds With ...

Page 9: ...y Or Death Keep PTO shield and all guards in place Keep away from moving parts Keep bystanders away Do not exceed the PTO speed of 2000 RPM See Owner s Manual For More Instructions 7179185 Rotating Fan Warning WARNING Avoid Serious Injury Or Death Do not operate with shields removed Do not modify 7179166 Maximum Trailer Weight Warning WARNING Towing An Improperly Loaded Trailer Can Cause Loss Of C...

Page 10: ...ncrease your risk of losing control Center and secure loads as low as possible in box Reduce speed and cargo on rough or hilly terrain Check for proper tire pressure X BRUTUS BRUTUS HD BRUTUS HDPTO MAXIMUM CARGO BOX LOAD 1250 lbs 567 kg 1250 lbs 567 kg 1250 lbs 567 kg ATTACHMENT ARM RATED CAPACITY 500 lbs 225 kg 500 lbs 225 kg TIRE PRESSURE IN PSI KPa FRONT 10 69 REAR 20 138 FRONT 20 138 REAR 20 1...

Page 11: ...a POLARIS vehicle always wear shatter proof goggles POLARIS recommends wearing approved Per sonal Protective Equipment PPE bearing markings such as VESC 8 V 8 Z87 1 or CE Make sure protective eye wear is kept clean Gloves Wear gloves for comfort and for protection from sun cold weather and other elements Boots Wear sturdy over the ankle boots Do not ride a POLARIS vehicle with bare feet Clothing W...

Page 12: ...has read this manual and all product labels To reduce tipover risk be especially careful when encoun tering obstacles and slopes and when braking on hills or dur ing turns This vehicle is for off road use only Never operate on public roads Always avoid paved surfaces Never consume alcohol or drugs before or while operating this vehicle Never operate at excessive speeds Always travel at a speed pro...

Page 13: ...est your brakes after leaving water If necessary apply them lightly several times to let friction dry out the pads Always be sure there are no obstacles or people behind your vehicle when operating in reverse When it s safe to proceed in reverse move slowly Avoid turning at sharp angles in reverse Always use the proper size and type of tires specified in this manual Always maintain proper tire pre...

Page 14: ...f with their function and effect on the vehicle Failure to operate the BRUTUS 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 Age Restrictions This vehicle is an ADULT VEHICLE ONLY...

Page 15: ...ye protection goggles Operating With a Load on the Vehicle The weight of both cargo and passengers impacts vehicle operation For your safety and the safety of others carefully consider how your vehicle is loaded and how to safely operate the vehicle Follow the instructions in this manual for loading tire pressure gear selection and speed Do not exceed vehicle weight capacities The vehicle s maximu...

Page 16: ...pect the entire machine for possible damage including but not limited to brakes throttle and steering systems Operating at Excessive Speeds Operating this vehicle at excessive speeds increases the operator s risk of losing control Always operate at a speed that s appropriate for the terrain the visibility and operating conditions your skills and your passengers skills Turning Improperly Turning im...

Page 17: ...ing on Slippery Terrain Failure to use extra caution when operating on excessively rough slippery or loose terrain could cause loss of traction loss of control accident or overturn Do not operate on excessively slippery surfaces Always reduce speed and use additional caution when operating on slippery surfaces Improper Hill Climbing Climbing hills improperly can cause loss of control or vehicle ov...

Page 18: ...ecially dry grass Attachment Arm System If Equipped The dealer explains the capabilities and restrictions of the BRUTUS utility vehicle attachment and accessories for each application The dealer demonstrates the safe operation according to Polaris instructional materials which are also available to operators The dealer can also identify unsafe modifications or use of unapproved attachments and acc...

Page 19: ...page 125 Front Bumper Brush Guard Radiator ROPS OPS Cab Frame Console Hip Bar Cargo Box Fuel Tank Cap Tailgate Latch Release Receiver Hitch Muffler Spark Arrester Tailgate Storage Compartment Under Seats Headlights Center Console Model HD and HDPTO Only Attachment Arm Model HD and HDPTO Only PTO Model HDPTO Only Taillights ...

Page 20: ...ential Switch Power Lift Assist Switch If Equipped Blank Switch Openings Available For Accessories HVAC Switches If Equipped OFF The engine is off Electrical circuits are off except Acc 12V ON Electrical circuits are on Electrical equipment can be used START After the wait to start indicator turns off turn the key to the START position to engage the electric starter The key returns to the ON posit...

Page 21: ...ential and operate in rear wheel drive Press the bottom of the switch to unlock the differential and allow the two rear drive wheels to operate independently See page 66 for differ ential lock operating instructions HVAC Switches If Equipped If equipped with a Cab with HVAC Heat and Air Condi tioning Fan Switch OFF Low Med High Air Conditioning Press top of switch to turn Air Conditioning ON botto...

Page 22: ...BRUTUS High gear is intended for use on hard packed surfaces with light loads 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 Always shift when the vehicle is stationary and the engine is at idle Tip Maintaining shift linkage adj...

Page 23: ...ring Wheel The steering wheel can be tilted upward or downward for rider preference Lift and hold the adjustment lever toward you while moving the steering wheel upward or downward Release the lever when the steering wheel is at the desired position ...

Page 24: ...hment with the PTO engaged Do NOT service the attachment in a raised position unless properly blocked and with all rotating components stopped Disengage PTO for road travel Joystick Lock Switch The joystick lockout switch Item 4 is used to active or lock out the joystick functions The joystick should be lockout when no attachments are installed This will keep the joystick from accidentally being a...

Page 25: ...evere injury or death Always avoid operating in a manner that could result in vehicle rollover Storage Compartments A storage compartment is located under both the driver s and operator s seat Trailer Hitch Bracket This vehicle is equipped with a receiver hitch bracket for a trailer hitch To avoid injury and property damage always heed the warnings and towing capacities outlined on pages 61 Brake ...

Page 26: ...at belts are secured for all riders before operating WARNING Falling from a moving vehicle could result in serious injury or death Always fasten your seat belt securely before operating or riding in the BRUTUS To wear the seat belt properly follow this procedure 1 For 3 point belts pull the seat belt latch downward and across your chest toward the buckle at the inner edge of the seat The belt shou...

Page 27: ...h the red release latch in the middle of the buckle to make sure it releases freely 3 Pull each seat belt completely out and inspect the full length for any damage including cuts wear fraying or stiffness If any damage is found or if the seat belt does not operate properly have the seat belt system checked and or replaced by an authorized POLARIS dealer 4 To clean dirt or debris from the seat belt...

Page 28: ...f any fuel that splashes on the instrument cluster Rider Information Center The rider information display is located in the instrument clus ter All segments will light up for 1 second at start up If the instrument cluster fails to illuminate a battery over voltage may have occurred and the instrument cluster may have shut off to protect the electronic speedometer If this occurs take the vehicle to...

Page 29: ...rouble Code in the engine manage ment system 10 Unit Lock N A on this model 11 Hour Meter Illuminates when the display 2 is showing hours 12 Low Oil Pressure Indicator LED icon illuminates low engine oil or hydraulic fluid pressure is sensed 13 Gear Position Indicator Displays gear selector position H High L Low N Neutral P Park Gear Signal Error shifter stuck between gears 14 Power Steering Syste...

Page 30: ...o change between Standard and Metric units of measurement follow these steps 1 Turn the key to the OFF position 2 Press and hold the MODE button while turning the key to the ON position 3 When the display flashes the distance setting tap the MODE button to advance to the desired setting 4 Press and hold the MODE button to save the setting and advance to the next display option 5 Repeat the procedu...

Page 31: ... the miles traveled by the vehicle on each trip To reset the trip meter 1 Toggle the MODE button to TRIP 1 2 To reset to 0 push and hold the MODE button until the distance display changes to 0 Engine Hours Engine hours are logged anytime the engine is running Total hours can not be reset Tachometer RPM Engine RPM can be displayed digitally PTO RPM when engaged is indicated after the PTO icon ...

Page 32: ...ur To set the clock follow these steps 1 Toggle the MODE button until the odometer is displayed 2 Press and hold the MODE button until the hour segment flashes Release the button 3 With the segment flashing tap the MODE button to advance to the desired setting 4 Press and hold the MODE button until the next segment flashes Release the button 5 Repeat steps 3 4 twice to set the 10 minute and 1 minu...

Page 33: ...ry voltage If volt age rises above 16 5 volts LCD backlighting and icons will turn off Programmed Service Interval The initial factory service interval setting is 50 hours Each time the engine is started the engine hours are subtracted from the service interval hours When the service interval reaches 0 the LCD wrench icon will flash for approximately 10 seconds each time the engine is started To c...

Page 34: ...the MODE but ton to toggle until CK ENG displays on the information display area 2 Press and hold the MODE button to enter the diagnostics code menu 3 A set of three numbers will appear in the information area 4 The first number located far left can range from 0 to 9 This number represents the total number of trouble codes present example 2 means there are 3 codes present 5 The second number locat...

Page 35: ... engine oil pressure diesel fuel leaks engine oil leaks coolant leaks hydraulic leaks and proper operation of the indicators and gauges 3 During the first hour of operation vary engine speed and the load on the engine Short periods of maximum engine speed and load are desirable Avoid prolonged operation at minimum or maximum engine speeds and loads for the next 4 to 5 hours 4 During the break in p...

Page 36: ...asteners Inspect condition and pressure Inspect ensure fastener tightness 112 Safety Signs Decals Check for damaged or missing signs decals Replace any signs that are damaged or missing Frame nuts bolts fasteners Inspect ensure tightness Fuel and oil Ensure proper levels 39 88 Coolant level Ensure proper level 92 Coolant hoses Inspect for leaks Travel Control Pedal Ensure proper operation 24 Indic...

Page 37: ...or Ultra Low Sulfur fuel should be used Bio Diesel fuels see pages 37 38 NEVER mix kerosene used engine oil or residual fuels with diesel fuel Water and sediment in the fuel should not exceed 0 05 by volume Keep the fuel tank and fuel handling equipment clean at all times Poor quality fuel can reduce engine performance and or cause engine damage Fuel additives are not recommended Some fuel additiv...

Page 38: ... suppliers Precautions and concerns regarding the use of bio fuels 1 Free methanol in FAME may result in corrosion of alumi num and zinc FIE components 2 Free water in FAME may result in plugging of fuel filters and increased bacterial growth 3 High viscosity at low temperatures may result in fuel delivery problems injection pump seizures and poor injection nozzle spray atomization 4 FAME may have...

Page 39: ...ing the specifica tions outlined above are not considered to be defects in mate rial or factory workmanship and are not covered under warranty The same applies to damages or other concerns induced by not complying with the recommended operating conditions of YANMAR engines with bio diesel fuel Handling Fuel WARNING Diesel fuel is flammable and explosive under certain conditions NEVER refuel with t...

Page 40: ... this vehicle See page 37 Bio diesel blended fuel has unique qualities that should be considered before using it in this vehicle Cold weather conditions can lead to plugged fuel system components and hard starting Bio diesel blended fuel is an excellent medium for micro bial growth and contamination which can cause corrosion and plugging of fuel system components Use of bio diesel blended fuel may...

Page 41: ...un the engine for at least 30 minutes NOTICE Bio diesel blended fuel does not have long term stability and should not be stored for more than three months Operating Conditions NOTICE Observe the following environmental operating conditions to maintain engine performance and avoid premature engine wear Avoid operating in the presence of chemical gases or fumes Avoid operating in a corrosive atmosph...

Page 42: ...and 6 until the engine starts 8 Allow the engine to warm to operating temperature For Models HD and HDPTO Vary the engine RPM slightly with the engine speed control lever to aid in warm up until the engine idles smoothly NOTICE Operating the vehicle immediately after starting could cause engine and hydraulic component damage Allow the engine to warm up for several minutes before operating the vehi...

Page 43: ...Model HD Raise the attachment arm See page 44 6 Apply the service brakes and shift the transmission into gear 7 Check your surroundings and determine your path of travel 8 Keeping both hands on the steering wheel slowly release the brakes and depress the travel control pedal with your right foot to begin driving Press the toe of the travel con trol pedal for forward travel press the heel of the tr...

Page 44: ... 5 Do not carry more than two passengers in the BRUTUS utility vehicle Do not carry more than one passenger in models HD and HDPTO 6 Allow a passenger to ride only in a passenger seat 7 Slow down Always travel at a speed appropriate for your skills your passengers skills and operating conditions Avoid unexpected or aggressive maneuvers that could cause discomfort or injury to a passenger 8 Vehicle...

Page 45: ...3 lockout feature All func tions of the joystick will be locked out To lockout the tilt function press the front of the attachment tilt lock switch Item 2 to lockout the joystick Item 3 tilt func tion Tip The utility vehicle engine must be running for the hydraulic sys tem to be activated Attachment Arm Operation Movement of the joystick controls the hydraulic cyl inders for the lift and tilt func...

Page 46: ... get immediate medical attention from a physician familiar with this injury Tip The utility vehicle engine must be running for the auxiliary hydraulic system to be activated Press the left side of the auxiliary hydraulic switch Item 2 to pressurize the female coupler Press the right side of the auxiliary hydraulic switch Item 3 to pressurize the male coupler Move the switch to the left or to the r...

Page 47: ... is made when the ball release sleeve slides forward on the female coupler To Disconnect Relieve hydraulic pressure Hold the male cou pler Retract the sleeve on the female coupler until the couplers disconnect Relieve Hydraulic Pressure Utility Vehicle And Attachment Utility Vehicle Lower the attachment arm fully and put the attachment flat on the ground Stop the engine Place the gear selector lev...

Page 48: ...em at higher engine rpm with the attachment under load Always engage the PTO system at a lower engine rpm and with the attachment under a no load condi tion The operator must be in the oper ator seat to engage the PTO sys tem If the operator exits the machine with the PTO engaged the PTO will shut off Reduce the engine speed On the PTO switch press the center button Item 1 and then pull up on the ...

Page 49: ... material is loaded the volume must be reduced to prevent overloading Exceeding the arm rated capacity can cause the following problems Difficult Steering Longer stopping distance Faster tire wear Loss of stability Reduced utility vehicle life Use the correct size bucket for the type and density of material being handled For safe handling of materials and avoiding vehicle damage the attachment or ...

Page 50: ...ar selector lever to LOW 3 Lower the attachment arm ant tilt the attach ment interface forward 4 Slowly drive forward until the front edge of the attachment inter face is completely under the top lip of the attachment Item 3 5 Tilt the attachment interface backward until the attachment is slightly off the ground 6 Move the gear selec tor lever to PARK and stop the engine See page 41 7 Install the ...

Page 51: ...ee page 46 5 Disconnect the PTO driveline if equipped See page 51 6 Remove the two retainers Item 1 and pins Item 2 both side 7 Install the two pins Item 3 and retainers Item 4 into the stor age position 8 Start the engine See page 41 Move the gear selector lever to LOW 9 Be sure the attach ment is fully lowered and the attachment is flat on the ground 10 Tilt the attachment interface forward Move...

Page 52: ...come to a complete stop before exiting the vehicle NOTICE Avoid PTO Driveline Damage Do not modify the attachment arm or PTO driveline Make sure PTO driveline is the correct length and that the u joints are in the correct phase Use only approved PTO drivelines designated for the attach ment and never use unapproved attachments WARNING Rotating Parts Can Cause Serious Injury Or Death Disengage the ...

Page 53: ... shields and guards in place Keep away from moving parts Keep bystanders away Do Not exceed 2000 PTO RPM Removing Stop the engine and exit the utility vehicle See page 41 Make sure the PTO drive line and all rotating com ponents have come to a complete stop before exit ing the utility vehicle Disconnect the PTO drive line Item 1 from the utility vehicle See your attachment Owner s Manual for addit...

Page 54: ...tain a steady speed when climbing hills If All Forward Speed Is Lost 1 Apply the brakes 2 Place the transmission in neutral and slowly allow the vehicle to roll straight downhill while applying light brake pressure to control speed If you Begin Rolling Downhill 1 Never apply engine power 2 Decelerate using the travel control pedal and apply the brake gradually until the vehicle is fully stopped 3 ...

Page 55: ...ve straight downhill Avoid descending a hill at an angle which would cause the vehicle to lean sharply to one side Travel straight downhill when possible For model HD and HDPTO Keep the heavy end of the vehicle uphill 3 Slow down 4 Apply the brakes slightly to aid in slowing 15 maximum BRUTUS HD and HDPTO 15 maximum ...

Page 56: ...g weather follow these precautions 1 Do not operate on excessively rough slippery or loose terrain 2 Slow down before entering slippery areas 3 Maintain a high level of alertness reading the trail and avoiding quick sharp turns which can cause skids 4 Engage all wheel drive before wheels begin to lose traction NOTICE Severe damage to the drive train may occur if the AWD is engaged while the wheels...

Page 57: ...always drive at a slight angle and at slow speed to allow one wheel at a time to go over the object This will allow maximum ground clearance for the utility vehicle and avoid PTO shaft dam age Driving in Reverse Follow these precau tions when operating in reverse 1 Always check for obstacles or people behind the vehicle Always inspect left and right fields of vision before back ing Always look in ...

Page 58: ...an attachment installed Follow these pro cedures when operating through water 1 Determine water depths and current before enter ing water 2 Choose a crossing where both banks have gradual inclines 3 Proceed slowly avoiding rocks and obstacles 4 Avoid operating through deep or fast flowing water WARNING The large tires on your BRUTUS may cause the vehicle to float in deep or fast flowing water whic...

Page 59: ...nly Lower the attachment arm and put the attachment flat on the ground 4 Move the gear selector lever to Park 5 For models HD and HDPTO only Move the engine speed control lever to low idle Disengage the PTO and make sure all rotating components are completely stopped 6 Turn the engine off and remove the key to prevent unau thorized use Parking on an Incline Avoid parking on an incline if pos sible...

Page 60: ...ING Unsecured loads can create unstable operating conditions which could result in loss of control of the vehicle OPERATE ONLY WITH STABLE AND SAFELY ARRANGED LOADS When handling off centered loads that cannot be centered securely fasten the load and operate with extra caution Always attach the tow load to the hitch point designated for your vehicle HEAVY LOADS CAN CAUSE BRAKING AND CONTROL PROBLE...

Page 61: ...d Capacity A plus B plus C plus D BRUTUS and BRUTUS HDPTO 1750 lb 794 kg BRUTUS HD 2000 lb 907 kg Maximum Attachment Arm Rated Capacity is determined by using the standard bucket and material of normal density such as dirt or dry gravel If other attachments such as Pallet forks are used the load is moved forward and the attachment arm capacity is reduced If very dense material is loaded the volume...

Page 62: ... operate the vehicle faster than 10 MPH 16 km h when towing See page 61 Towing a trailer increases braking distance 3 Do not tow more than the recommended weight for the vehicle See the towing capacity chart on previous page and the spec ifications charts beginning on page 59 4 Attach a trailer to the trailer hitch bracket only Do not attach a trailer to any other location or you may lose control ...

Page 63: ...ver operate the dump lever without ensuring that the load is positioned evenly or at the front of the box 8 Stand clear and pull up on the cargo box release lever 9 Lift the front of the cargo box to dump the cargo 10 Lower the cargo box and push down securely to latch WARNING Operating the vehicle while the cargo box is raised could result in severe injury The box could close unexpectedly and cau...

Page 64: ...er Can Cause Serious Injury or Death Keep the attachment arm as low as possible Turn on level ground Slow down when turning Go up and down slopes not across them Keep the heavy end of the vehicle uphill Do not exceed vehicle load capacity Check for adequate traction Raise the bucket only high enough to avoid obstructions on rough ground Tip When both ar empty or when both are loaded the front and ...

Page 65: ...vel ground Do not exceed vehicle load capacity shown on sign decal in cargo box Failure to obey warnings can cause vehicle rollover and can cause serious injury or death Drive backward away from the material Emptying Keep the bucket low when moving to the area where you want to dump the material Move the machine slowly to the dump area While raising the attachment arm Item B tilt the bucket for wa...

Page 66: ...on Drive backward to level loose material Pull the joystick backward Item B to unlock the attachment arm from the float position Backfilling Lower the attachment arm Item A and put the cutting edge of the bucket on the ground Item D Drive forward to the edge of the hole to push the material into the hole Tilt the bucket forward Item D as soon as it is past the edge of the hole If necessary raise t...

Page 67: ...nt hubs are driving they will not release until the rear wheels regain traction In some situations the front gearcase may remain locked after turning the AWD switch off If this occurs you may notice increased steering effort and some vehicle speed restriction Perform the following procedure to unlock the front gearcase 1 Stop the vehicle Operate in reverse for at least 10 feet 3 m 2 Stop completel...

Page 68: ...nstructions on machine signs decals Replace damaged or missing decals Do not wear loose or bulky clothing around the PTO or other mov ing parts Keep bystanders away from PTO driven equipment and never allow children near machines Read and understand the manuals for the PTO driven equipment and be aware of safe operating procedures and hazards that may not be readily apparent Always walk around equ...

Page 69: ...ith each type of attachment Know that when attachments are installed the utility vehicle braking distance increases Before beginning operation inspect the work area for unsafe conditions Look for drop offs or rough terrain Have underground utility lines gas water sewer irrigation etc located and marked Remove objects or other construction material that could dam age the utility vehicle or cause pe...

Page 70: ...r your attachment See the attachment Owner s Manual for the correct attachment operating RPM With engine RPM at 3600 the PTO shaft will rotate at approximately 2000 RPM Adjust engine RPM to meet the attachment RPM requirement Tip The maximum PTO speed for various attachments may vary See the attachment Owner s Manual for the maximum speed recommended for your attachment Tip When driving over objec...

Page 71: ...r blocks before removing the attachment arm from the vehicle 3 Move the gear selector lever to PARK and stop the engine See page 41 WARNING Avoid Injury Keep fingers and hands out of pinch points when removing and installing the attachment arm Tip When the pin Item 2 is removed from the tilt cyl inder the interface will be free to tilt down to the ground Support the interface while the pin is bein...

Page 72: ...tem 1 if equipped If not equipped with the Stow Kit cylinder retainer a heavy tie strap can be used to secure the cylinder to the grille in the storage position Position the cylinder to the frame and install the pin Item 3 and the retainer pin Item 3 to secure the lift cylinder in the storage position Tip When the pins Item 5 are removed from the attachment arm it will be free to tilt down to the ...

Page 73: ...ed in front of the attachment arm 2 Remove the retainer pins and pins from the attachment arm both sides 3 Raise the attachment arm and position it to the vehicle mounting frame Install the two pins Item 1 and retainer pins Item 2 4 Remove the lift cylin der retainer pin Item 3 and the pin Item 4 5 Remove the tilt cylin der from the Stow Kit Item 5 Lower the tilt cylinder down and rest the rod end...

Page 74: ...er fully 8 Extend the tilt cylinder fully 9 Press the top of the joystick lockout switch to lockout the joystick Turn the key to the OFF position and exit the utility vehicle 10 Raise the interface until it is aligned with the rod end of the lift cylinder Install the pin Item 1 and retainer pin Item 2 11 Rotate the interface upward until it is aligned with the rod end of the tilt cylinder Install ...

Page 75: ...op the engine See page 41 2 Make sure the PTO driveline and all rotating components have come to a complete stop before exiting the utility vehicle 3 Install the utility vehicle on jack stands See page 111 4 Remove the four bolts Item 1 and remove the shield Item 2 Installation Tighten the bolts to 7 8 ft lb 9 10 Nm torque 5 Remove the eight bolts Item 3 and remove the belly pan Item 4 Installatio...

Page 76: ...hten the bolts to 18 19 ft lb 24 26 Nm torque 9 Reinstall the belly pan after the PTO shaft has been removed 10 Place all the parts in a secure dry area for installation at a later date 11 Remove the machine from the jack stands See page 111 12 The utility vehicle will now have additional ground clear ance foe off road use Installing 1 Stop the engine and exit the vehicle See page 41 2 Make sure t...

Page 77: ...e at www gpoaccess gov ecfr Exhaust Emission Control System Exhaust emissions are controlled by engine design A fuel injection system controls fuel delivery The engine and fuel injection components are set at the factory for optimal perfor mance and are not adjustable Your engine is designed to operate on low sulfur or ultra low sulfur diesel fuel only Use of any other fuel may result in your engi...

Page 78: ...Severe Use Definition Frequent immersion in mud water or sand Racing or race style high RPM use Prolonged low speed heavy load operation Extended idle Short trip cold weather operation Pay special attention to the oil level A rise in oil level during cold weather can indicate contaminants collecting in the oil sump or crankcase Change oil immediately if the oil level begins to rise Monitor the oil...

Page 79: ...avel Daily Ensure proper operation Engine speed control lever if applicable Travel control pedal Head lights Tail lights Daily Check for proper operation Indicator lights Switches E Air filter Daily Inspect filter element replace as needed or every 150 hours E Air intake sediment drains Daily Inspect drains on bottom of engine air intake duct and air filter housing for obstructions Cooling system ...

Page 80: ...ns Decals Daily Check for damaged signs decals replace any that are damaged Seat belts Daily Check the condition of the seat belts clean or replace seat belt retrac tors as needed Steering suspension Daily Inspect for broken parts loose hardware and free operation Tires Daily Check for wear damage and correct tire pressure Wheels fasteners Daily Check for loose wheel nuts and tighten to the correc...

Page 81: ...e hydraulic fluid filter and reservoir breather cap every 400 hours thereafter Battery 50 H 1 M Check terminals clean test E Fuel filter water separator 50 H 3 M Drain every 50 hours normal conditions with quality fuel or daily severe conditions with poor fuel quality General grease lubrication 50 H 3 M 500 800 Lubricate all grease fittings pivots etc E Air intake ducts adapters 50 H 6 M Inspect d...

Page 82: ...2 M 1000 1600 Inspect replace as needed Front Gearcase lubricant Demand Drive Plus 100 H 12 M 1000 1600 Change lubricant Transmission lubricant AGL Gearcase Lubri cant 100 H 12 M 1000 1600 Change lubricant Hydraulic hydrostatic and power steering hoses 100 H 12 M 1000 1600 Inspect for damage and leaks repair or replace as needed Radiator 100 H 12 M 1000 1600 Inspect clean external surfaces Wiring ...

Page 83: ... adjustment 200 H 24 M 2000 3200 Inspect adjust if necessary or when parts are replaced D Brake fluid 200 H 24 M 2000 3200 Change every two years DOT 4 Spark arrester exhaust clean out 300 H 36 M Remove plug and clean out Hydraulic hydrostatic system 400 H Replace hydraulic fluid filter and reservoir breather cap PTO gearbox lubricant if equipped 400 H 12 M Change lubricant PTO shaft u joints if e...

Page 84: ...al lubrication interval Item Lube Method Engine Oil See page 87 Brake Fluid DOT 4 Maintain level between fill lines See page 101 Main Gearcase Oil Transmission AGL PLUS Transmission Fluid See page 89 Front Gearcase Oil Demand Drive PLUS Fluid See page 90 Front Prop Shaft Yoke and PTO shaft POLARIS Premium U Joint Lube Locate fittings and grease 3 pumps maximum See page 120 Front and rear suspensio...

Page 85: ...Item 1 in PARK move the PTO Item 2 to the ON position the engine must not start If the engine starts in any of these positions see your dealer for service PTO Interlock System Model HDPTO Description The utility vehicle is equipped with a PTO Interlock System The following must be in place before the PTO can be engaged The operator must be seated in the operators seat Inspecting To check the funct...

Page 86: ... HD And HDPTO Models Only Position the utility vehicle on a flat level surface Put the gear selector in PARK and stop the engine Exit the utility vehicle Check the travel control pedal Item 1 for excessive free play The correct amount of total free travel on the travel control pedal is 7 6 mm 0 30 in The engine speed control lever Item 2 will be used to control engine RPM When on flat level ground...

Page 87: ...ders and on a flat level hard surface Start the engine See page 41 Operate the machine until engine and hydrau lics are at operating tem perature Move the gear selector lever to high Traveling in a straight path accelerate at a high rate and monitor engine RPM The engine RPM will increase moderately and then increase quickly to approxi mately 3200 3700 RPM and maintain this RPM If engine speed doe...

Page 88: ...ture expected during operation See the chart below Oil Viscosity Ambient Air Temperature Chart Oil Check The oil dipstick is located on the engine under the passenger seat Tip Engine oil should be checked cold or allow time for the oil to drain back into pan before checking to prevent overfilling 1 Position the vehicle on a level surface 2 Stop the engine 3 Tilt the rear cargo box to access the en...

Page 89: ...towels beneath the oil filter Using an oil filter wrench turn the filter counter clockwise to remove it 9 Using a clean dry cloth clean the filter sealing surface on the crankcase 10 Lubricate the o ring on the new filter with a film of fresh engine oil Check to make sure the o ring is in good condi tion 11 Install the new filter and turn by hand until the filter gasket contacts the sealing surfac...

Page 90: ...ed oil as needed 3 Reinstall the fill plug Torque to specification Oil Change The drain plug is located on the bottom of the transmission Access the drain plug from under the rear of the vehicle 1 Remove the fill plug 2 Place a drain pan under the vehicle at the location of the drain plug 3 Remove the drain plug Allow the oil to drain completely 4 Clean and reinstall the drain plug with a new seal...

Page 91: ...ill plug is located on the right side of the front gearcase 1 Position the vehicle on a level surface 2 Remove the fill plug Check the oil level 3 Add the recom mended oil as needed 4 Reinstall the fill plug Torque to specification Oil Change 1 Support the vehicle securely on jack stands 2 Remove the fill plug 3 Place a drain pan under the drain plug on the bottom of the gearcase 4 Remove the drai...

Page 92: ...tem when adding coolant Mixing types can result in damage to the cooling system POLARIS recommends the use of POLARIS Premium 60 40 anti freeze coolant or a 50 50 mixture of high quality alumi num compatible anti freeze coolant and distilled water POLARIS Premium 60 40 is already premixed and ready to use Do not dilute with water Always follow the manufacturer s mixing recommendations for the free...

Page 93: ... coolant must be added often or if the overflow bottle runs com pletely dry there may be a leak in the system Have the cooling system inspected by your POLARIS dealer Radiator Cool ant Level 1 Lift the hood 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 2 Slowly remove the radiato...

Page 94: ...re filter box located at the left ROPS OPS post See page 95 3 Dry any water that is present in the air cleaner housing Filter replacement is required if water is present 4 Remove the air intake resonator box and drain any water that is present Dry the box thoroughly NOTICE If you believe water has entered the engine Do Not start the engine Engine damage will result Take the vehicle to your dealer ...

Page 95: ... screw to relieve fuel pressure in the filter Do not tighten the screw at this time 4 Reach under the fuel filter and slightly loosen the drain valve until the fluids drain from the drain hole Do not completely unscrew the drain valve 5 When fluids stop drain ing from the valve tighten the valve firmly by hand only Tighten the bleed screw 6 With the gear selector in Park turn the key to the ON pos...

Page 96: ...amage If any damage is found replace the pre filter assembly 3 DO NOT use compressed air to clean the pre filter open Use a damp cloth and clean the inside of the pre filter opening Installation 1 Insert the two tabs on the pre filter assembly into the side frame Rotate the pre filter into the frame and make sure the latch securely retains the pre filter to it s original location Cleaning Intake W...

Page 97: ... cover clips Remove the air box cover 3 Remove the air filter assembly with a pull ing and twisting motion Use care to avoid damaging the filter element NOTICE Operating a diesel engine with a soiled or damaged air filter can result in engine damage Do not attempt to wash the filter Always replace a soiled or damaged filter with a new filter 4 Clean any dirt or deposits from the air box 5 Reinstal...

Page 98: ...er the attachment arm and put the attachment flat on the ground See page 44 Move the gear selector lever to Park stop the engine and exit the utility vehicle See page 41 Raise the cargo box See page 62 Check the fluid level in the sight gauge The fluid level is correct when at the center of the sight gauge Use only recommended Polaris hydraulic fluid when adding or changing the hydraulic fluid See...

Page 99: ... cardboard or wood to find leaks Do not use your bare hand Wear safety goggles If fluid enters skin or eyes get immediate medical attention from a physician familiar with this injury Place a container under the filter Recycle or dis pose of used oil in an environmentally safe manner Remove the hydraulic fil ter Clean the surface of the filter housing where the filter contacts the hous ing Put clea...

Page 100: ...the tank Remove the fill breather cap Remove and clean the hydraulic fill screen Use low air pressure to clean the screen Remove the hydraulic fil ter see page 98 Install a new filter Dispose of the used fluid in an environmentally safe manner Install the fill screen and fill to the proper level See Page 99 Install and tighten the fill breather cap Lower the cargo box See page 62 WARNING Avoid Inj...

Page 101: ... accumu lated carbon from the exhaust pipe 1 Remove the arrester clean out plug located on the bottom of the muffler 2 Place the transmission in Park Start the engine 3 Press the brake pedal and then press the travel control pedal to increase engine RPM Purge accumulated carbon from the system by momentarily revving the engine sev eral times 4 If carbon is expelled partially cover the exhaust outl...

Page 102: ...uid in the reservoir are unknown 1 Position the vehicle on a level surface 2 View the brake fluid level at the reservoir in the driver s side wheel well 3 The level should be between the upper MAX and lower MIN level lines 4 If the fluid level is lower than the upper level line add brake fluid to the upper MAX line 5 Apply the brake forcefully for a few seconds and check for fluid leakage around t...

Page 103: ...djustment 1 Loosen the jam nuts Item 5 and 6 2 Rotate the two jam nuts Item 5 and 6 as needed to move the gear selector lever up or down so the lever does not contact the slot at either the bottom or top position 3 Evenly tighten the two jam nuts Item 5 and 6 until tight to the cable mount 4 Check operation of the gear selector Have the vehicle in an open area with no bystanders or place the vehic...

Page 104: ...e set the spring rate for optimal performance for use with the various attachments that can be installed on the attachment arm For the BRUTUS model Adjust the rear and front shock absorber springs by rotating the adjustment cam either clock wise or counterclockwise to increase or decrease spring ten sion For the BRUTUS HD and HDPTO models Adjust the rear shock absorber springs by rotating the adju...

Page 105: ... at the mid span Item 3 of the belt when 20 lb 89 N is applied to the belt 4 If the belt tension is not correct loosen the mounting bolt Item 4 and adjustment bolt Item 5 5 Move the top of the alternator Item 6 to tighten the belt 6 Tighten the mounting and adjustment bolts Item 4 and 5 Tighten bolt Item 4 to 15 ft lb 20 Nm and tighten bolt Item 5 to 28 ft lb 38 Nm torque 7 Install the shield Item...

Page 106: ...belt deflection at the mid span Item 3 of the belt when 20 lb 89 N is applied to the belt 5 If the belt tension is not correct loosen the mounting bolt Item 4 and adjustment bolt Item 5 6 Move the top of the compressor to tighten the belt 7 Tighten the mounting and adjustment bolts Item 4 and 5 Tighten bolt Item 4 to 15 ft lb 20 Nm and tighten bolt Item 5 to 28 ft lb 38 Nm torque 8 Install the shi...

Page 107: ...e engine and exit the vehicle See page 41 2 Turn the two fasteners Item 1 counterclock wise 1 4 turn and open or remove the cover Item 2 3 Use low pressure air or water to clean the con denser Item 3 4 Close the door Item 2 and turn the two 1 4 turn fasteners Item 1 clock wise Filter Cleaning The air conditioning filter is located below the dash 1 Remove the two fasten ers Item 4 and remove the fi...

Page 108: ...ss the PTO clutch See page 25 Use a feeler gauge Item 1 and insert the end of the feeler gauge into the edge of the clutch pack to a depth of 0 31 in 8 mm and measure the clearance Measure in three places in the three openings in between the three adjusting nuts to determine that the clearance is the same for all three areas on the clutch pack The correct clearance is 0 014 in 0 35 mm Tip Do not i...

Page 109: ...p the engine and exit the vehicle See page 41 Raise the cargo box See page 62 The drive belt idler Item 1 is under constant spring load to keep the belt at the correct tension No adjustment can be made If belt slippage is noticed the belt and or the constant tension pulley must be replaced Inspect belt con dition If belt wear including the side of the belt is visible belt replacement is needed See...

Page 110: ...the T40 wrench Item 2 that is included in the tool kit or an equivalent tool and a piece of tubing that fits snuggly over the tool Mark the tool at two places at 0 43 inches 11 mm and at 2 17 inches 55 mm Slide a piece of tubing over the tool to use as a stop and set it at the 2 17 inches 55 mm mark The correct oil level is between the tip of the tool and the 0 43 inches 11 mm mark If the oil leve...

Page 111: ...e drain plug Item 1 and tighten to 11 ft lb 15 Nm torque 5 The PTO gear box requires special syn thetic fluid Use only recommended fluid in the PTO gear case See page 110 for the correct fluid specifications 6 Thoroughly clean the area around the breather tube fitting Item 2 and remove the fitting 7 Install a piece of clear tubing Item 4 on the end of the gear case fluid bottle Item 5 Add the prop...

Page 112: ...ns are necessary before operating or servicing machine Read and understand the Operator s Manual Operator s Handbook if equipped and signs decals on machine Follow warnings and instructions in the manuals when performing repairs adjustments or service Check for correct function after adjustments repairs or service Untrained operators and failure to follow instructions can cause injury or death Pla...

Page 113: ...els on the vehicle Always use original equipment size and type when replacing tires Tire Tread Depth Always replace tires when tread depth is worn to 1 8 3 mm or less Axle and Wheel Nut Torque Specifications Inspect the following items occasionally for tightness and if they ve been loosened for maintenance service Do not lubricate the stud or the lug nut WARNING 1 8 3 mm Fastener Location Nut Torq...

Page 114: ...e a cotter pin installed See your POLARIS dealer 4 Attach the wheel nuts and washers and finger tighten 5 Carefully lower the vehicle to the ground 6 Torque the wheel nuts to specification See page 112 Lights Poor lighting can result in reduced visibility when driving Headlight and taillight lenses become dirty during normal operation Clean lights frequently and replace burned out lamps promptly A...

Page 115: ...h the headlight approximately 25 ft 7 6 m from a wall 2 Place the transmission in gear Engage the park brake 3 Measure the distance from the floor to the center of the headlight and make a mark on the wall at the same height 4 Apply the brakes Start the engine Turn on the headlights 5 Observe the headlight aim The most intense part of the headlight beam should be aimed 8 20 cm below the mark place...

Page 116: ... not be working prop erly please see your POLARIS dealer The fuse panel is located below the seat between the operator and passenger For the BRUTUS model remove the seat For HD and HDPTO models the center console will need to be removed Additional relays and fuses are also located in the same area as the fuse and relay panels 1 Relay Radiator fan motor 2 Relay HVAC if equipped 3 In line fuse 30A H...

Page 117: ... the terminals with dielectric grease or petroleum jelly Battery Removal 1 Remove the seat The battery is located under the passen gers side of the vehicle 2 Disconnect the black battery cable first 3 Disconnect the red battery cable last 4 Remove the battery hold down strap 5 Lift the battery out of the vehicle Battery Installation Using a new battery that has not been fully charged can dam age t...

Page 118: ...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 volt...

Page 119: ...he distance between the chalk marks and record the dimension We will call this dimension B 6 The difference between dimension A and B is the toe alignment The recommended toe tolerance is 0 125 0 25 inch 3 17 6 35 mm toe out This means the measure ment A in front of the tire should be wider than the mea surement B at the rear of the tire Toe Adjustment Tip Be sure the steer ing wheel is straight a...

Page 120: ...e Periodic Maintenance Chart begin ning on page 78 Always use a good quality lithium based multi purpose grease Lubricate the following 1 Lower A Arms both sides 2 Upper A Arms both sides 3 Trailing Arm Rear Pivot both sides 4 Trailing Arm Front Pivot both sides 5 Upper Suspension Arm 2 1 1 3 4 5 ...

Page 121: ... 6 Drive Shaft in front of transmission 7 Lift Cylinder Base End 8 Lift Cylinder Rod End 9 Tilt Cylinder Base End 10 Tilt Cylinder Rod End bottom side of cylinder rod 11 Attachment Arm Pivot Rear both sides 12 Attachment Arm Pivot Front both sides 6 10 12 9 7 8 11 11 12 ...

Page 122: ...s which can scratch the fin ish 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 polish ing Old or reused cloths and pads may contain dirt particles that will scratch the finish If a high pressure water system is used for cleaning not rec ommended exercise extreme caution The water may damage co...

Page 123: ...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 polish ing Old or reused cloths and pads may contain dirt particles that will scratch the finish ...

Page 124: ...ance Chart beginning on page 78 Battery Maintenance See page 117 for storage and charging procedures Fluid Levels Inspect the fluid levels Add or change fluids as recommended in the Periodic Maintenance Chart beginning on page 78 Front gearcase fluid Transmission fluid Hydraulic Hydrostatic fluid Brake fluid change every two years and any time the fluid looks dark or contaminated Coolant test stre...

Page 125: ... the Periodic Mainte nance Chart beginning on page 78 Transporting the BRUTUS Follow these procedures when transporting the vehicle 1 Apply the brakes 2 Stop the engine 3 Place the transmission in PARK 4 Secure the fuel cap oil cap and seat 5 Always tie the frame of the BRUTUS to the transporting unit securely with suitable straps or chains Do not attach tie straps to the front A arm bolt pockets ...

Page 126: ... Coolant Capacity Radiator 6 2 qts 5 9 l 6 9 qts 6 5 l Coolant Capacity Overflow 7 5 oz 222 ml Hydraulic Fluid Capacity Reservoir at cen ter of sight gauge 2 75 qts 2 61 l 2 75 qts 2 61 l 2 75 qts 2 61 l Hydraulic Fluid Capacity System 7 2 qts 6 81 l 8 4 qts 7 95 l 8 4 qts 7 95 l A C Refrigerant R134A if applicable 0 86 lbs 1 9 kg Front Differential 6 8 oz 200 ml Main Gear Case 41 oz 1200 ml PTO G...

Page 127: ...low PTO NA NA 7 2 in 18 4 cm Min Turning Radius Turf Mode 90 in 229 cm Min Turning Radius Two Wheel Drive 110 in 280 cm Min Turning Radius 4 Wheel Drive 110 in 280 cm Engine YANMAR 3 Cylinder Inline Diesel Displacement 55 1 in3 904 cc Bore x Stroke 2 83 in x 2 91 in 72mm x 74mm Lubrication System Pressurized Wet Sump High Idle 3700 100 RPM Low Idle 1350 100 RPM Alternator Output 12V DC 90A Startin...

Page 128: ... 12 Tire Pressure Front 10 psi 69 KPa 20 psi 138 KPa 20 psi 138 KPa Tire Pressure Rear 20 psi 138 KPa 20 psi 138 KPa 20 psi 138 KPa Brakes Front Rear Foot Activated 4 wheel hydraulic disc Hood Headlight 60 55W High Low Halogen Taillights 10 L E D 28W Brake Light 10 L E D 3 1W Indicator Light 1 0 W Hydraulic Pump Engine driven gear type Pump Capacity 7 6 gpm 28 8 l 3600 RPM Steering Flow 2 2 gpm 8 ...

Page 129: ...il Change Kit Winter Gearcase Transmission Lubricants 2878068 AGL PLUS Transmission Fluid qt 95 l 2878069 AGL PLUS Transmission Fluid gal 3 8 l 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 60 40 Coolant gal 3 8 l 2871534 60 40 Coolant qt 95 l Hydraulic Fluid 2879746 Polaris Hydraulic Fluid gal 3 8 l PTO Gearbox ...

Page 130: ...eason Grease 3 oz 89 ml cartridge 2871423 Premium All Season Grease 14 oz 414 ml cartridge 2871460 Starter Drive Grease 2871515 Premium U Joint Lube 3 oz 89 ml cartridge 2871551 Premium U Joint Lube 14 oz 414 ml cartridge 2871329 Dielectric Grease NyogelTM Miscellaneous 2872189 DOT 4 Brake Fluid 2859044 POLARIS Battery Charger Yuasa 1 5A ...

Page 131: ... battery voltage Recharge the battery to 12 8 VDC Mechanical failure See your dealer Defective glow plug Inspect and replace Defective stop solenoid Replace Defective fuel pump Replace Possible Cause Solution Poor fuel quality or incorrect fuel Replace with recommended fuel Low fuel level Refuel Clogged fuel filter Replace Clogged air filter Replace Water present in fuel Replace with new fuel Kink...

Page 132: ...ARIS Initial dealer preparation and set up of your vehicle is very important in ensuring trouble free operation Purchasing a machine in the crate or without proper dealer set up will void your warranty coverage WARRANTY COVERAGE AND EXCLUSIONS LIMITATIONS OF WARRANTIES AND REMEDIES This POLARIS limited warranty excludes any failures that are not caused by a defect in material or workmanship THIS W...

Page 133: ...warranty service you must take it to a POLARIS Servicing Dealer When requesting warranty service you must present your copy of the Warranty Registration From to the dealer THE COST OF TRANSPORTATION TO AND FROM THE DEALER IS YOUR RESPON SIBILITY POLARIS suggests that you use your original selling dealer however you may use any POLARIS Servicing Dealer to perform warranty service In the Country whe...

Page 134: ...r product is registered outside of the country where it was purchased and you have not followed the procedure set above your product will no lon ger be eligible for warranty or service bulletin coverage of any kind other than safety bulletins Products registered to Government officials or military personnel on assignment outside of the country where the product was pur chased will continue to be c...

Page 135: ...lated components include any engine parts related to the following systems he following parts are also considered emission related components for exhaust emissions The following parts are considered emission related components for evapo rative emissions As related to the evaporative emission control system he exclusive remedy for breach of this limited warranty shall be at the exclusive option of ...

Page 136: ...ny warranty claims for failures that have been caused by the owner s or operator s improper maintenance or use by accidents for which POLARIS has no responsibility or by acts of God Any qualified repair shop or person may maintain replace or repair the emission control devices or systems on your vehicle POLARIS recommends that you contact an authorized POLARIS dealer to perform any service that ma...

Page 137: ...136 MAINTENANCE LOG Use the following chart to record periodic maintenance DATE MILES KM OR HOURS TECHNICIAN SERVICE PERFORMED COMMENTS DATE MILES KM OR HOURS TECHNICIAN SERVICE PERFORMED COMMENTS ...

Page 138: ... In Period 34 Breather Cap hydraulic 99 C Cab Frame Occupant Protective Structure 24 Capacity Weight 60 Cargo 59 60 61 Cargo Box Capacity 60 Cargo Box Dumping 62 Center Console 23 Chart Gearcase Specifications 89 Check Engine 33 Check Hydraulic 33 Cleaning and Storage 125 126 127 Clock 31 Clothing 10 Cold Weather Operation 39 40 Component Locations 18 Console 21 22 23 Coolant Level Overflow Bottle...

Page 139: ...itch 24 Horse Power Management 85 HVAC Switched 20 Hydraulic Breather Cap 9 I Idle RPM 126 Ignition Switch 19 Indicator Lights 20 Information Display Area 29 Information Labels 6 Inspection Pre Ride 35 Inspection Shift Cable 102 Installing Attachment 49 Installing attachment Arm 70 Installing PTO 51 Instrument Cluster 27 29 30 31 32 33 Interference Electromagnetic 76 J Joystick Lock Switch 23 Swit...

Page 140: ...ch 24 Refueling 39 Relays 115 Removing Attachment Arm 70 Removing Attachments 50 Removing The PTO 52 Removing the Vehicle from Storage 124 Reverse Operation 56 Rider Information Center 27 Riding Gear 10 Rollover Protective Structure 24 ROPS OPS Cab Frame 24 S Safety Labels 6 8 9 Safety Rules Fof PTO 67 Safety Symbols 4 Safety Warnings 14 16 17 Protective Apparel 14 Seat Belts 14 25 26 Seat Removal...

Page 141: ...porting the Vehicle 124 Travel Direction Pedal Maintenaance 85 Tread Depth 112 Trip Meter 30 TROUBLESHOOTING 130 V Vehicle Identification Numbers 5 Vehicle Immersion 93 Vehicle Transport 124 VIN 5 W Warning Symbols 4 WARRANTY 131 Washing the Vehicle 121 Water Separator 94 Water Immersion of Vehicle 93 Weight Capacity 60 Wheel Installation 113 Wheel Nut Inspection 112 Wheel Nut Torque 112 Wheel Rem...

Page 142: ...can occur with another vehicle With passengers under age twelve or who cannot comfortably reach the floor and hand holds With unapproved accessories they may seriously affect stability NEVER Operate ALWAYS Wear your seat belt Vehicle rollover could cause severe injury or death Wear eye protection and keep hands and feet in vehicle at all times Reduce speed and use extra caution when carrying passe...

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