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Polaris M1400, Owner'S Manual

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Polaris M1400 Owner'S Manual Download Page 56

54

MAINTENANCE

Lubrication Recommendations

Check and lubricate all components at the intervals outlined in the Periodic Maintenance 
Chart beginning on page 51, or more often under severe use, such as wet or dusty conditions. 
Items not listed in the chart should be lubricated at the general lubrication interval.

Item

Lube

Method

Engine Oil

PS-4 5W-50 4-Cycle Oil

See page 55.

Brake Fluid 

DOT 4 Brake Fluid

See page

 

68.

Main Gearcase Oil (Transmission)

AGL Gearcase Lubricant & Transmission 
Fluid

See page

 

58.

Front Gearcase Oil (if equipped)

Demand Drive Fluid

See page

 

59.

Front Prop Shaft Yoke (if equipped)

U-Joint Grease

Locate fittings and grease (3 
pumps maximum). 

Summary of Contents for M1400

Page 1: ...Owner s Manual for Maintenance and Safety POLARIS M1400 ...

Page 2: ...he safety precautions could result in serious injury or death WARNING The engine exhaust from this product contains chemicals known to the State of California to cause cancer birth defects or other reproductive harm For videos and more information about a safe riding experience with your Polaris vehicle scan this QR code with your smartphone ...

Page 3: ...for all utility and recreational vehicles manufactured in the world today Many years of experience have gone into the engineering design and development of your POLARIS vehicle making it the finest machine we ve ever produced For safe and enjoyable operation of your vehicle be sure to follow the instructions and recommendations in this owner s manual Your manual contains instructions for minor mai...

Page 4: ... the actual vehicle and the information presented in this publication Depictions and or procedures in this publication are intended for reference use only No liability can be accepted for omissions or inaccuracies Any reprinting or reuse of the depictions and or procedures contained within whether whole or in part is expressly prohibited The original instructions for this vehicle are in English Ot...

Page 5: ...TS Introduction 4 Safety 8 Features and Controls 18 Operation 29 Winch Guide 41 Emission Control Systems 50 Maintenance 51 Specifications 82 POLARIS Products 84 Troubleshooting 85 Warranty 88 Maintenance Log 93 Index 95 ...

Page 6: ...liar with their meanings before reading the manual The safety alert symbol indicates a potential personal injury hazard DANGER A DANGER indicates a hazardous situation that if not avoided will result in death or serious injury WARNING A WARNING indicates a hazardous situation that if not avoided could result in death or serious injury CAUTION A CAUTION indicates a hazardous situation that if not a...

Page 7: ... Vehicle Association ROHVA training course at www rohva org This vehicle is an ADULT VEHICLE ONLY You MUST be at least age 16 and have a valid driver s license to operate this vehicle No person under the age of 12 may ride as a passenger in this vehicle All riders must be able to sit with backs against the seat both feet flat on the floor and both hands on the steering wheel if driving or on a pas...

Page 8: ...placement key for your vehicle please contact customer service Be prepared to provide your key number and VIN Remove the spare key and store it in a safe place A key can be duplicated only by ordering a key blank using your key number and mating it with one of your existing keys The key switch must be replaced if all keys are lost Vehicle Model Number ______________________________________________...

Page 9: ... condition The environment was controlled as indicated by the test procedure s The uncertainty of vibration exposure measurement is dependent on many factors including Instrument and calibration uncertainty Variations in the machine such as wear of components Variation of machine operators such as experience or physique Ability of the worker to reproduce typical work during measurements Environmen...

Page 10: ...cle Do your part to prevent injuries Do not allow careless or reckless driving Make sure operators are 16 or older with a valid driver s license Do not let people drive or ride after using alcohol or drugs Do not allow operation on public roads unless designated for off highway vehicle access collisions with cars and trucks can occur Do not exceed seating capacity 2 occupants 7179978 Clutch Cover ...

Page 11: ... if equipped Vehicle rollover could cause severe injury or death Wear eye protection and keep hands and feet in vehicle at all times Wear a helmet when appropriate Reduce speed and use extra caution when carrying a passenger Avoid sharp turns or turns while applying heavy throttle Operate slowly in reverse avoid sharp turns or sudden braking Make sure passenger reads and understands all safety lab...

Page 12: ...hirt A hard hat or helmet and approved eye protection are recommended when appropriate for working or riding conditions POLARIS recommends wearing approved eye protection bearing markings such as VESC 8 V 8 Z87 1 or CE Never operate or ride in this vehicle while barefoot or while wearing sandals or tennis shoes Workplace safety regulations may require the use of safety glasses safety shoes and a h...

Page 13: ...roved eye protection are recommended when appropriate for working or riding conditions Seat belt must be worn at all times Always keep hands and feet inside the vehicle at all times Always keep both hands on the steering wheel and both feet on the floorboards of the vehicle during operation Never permit a guest to operate this vehicle unless the guest has read this manual and all product labels To...

Page 14: ...here possible Always check for obstacles before operating in a new area Never attempt to operate over large obstacles such as large rocks or fallen trees Always follow the proper procedures outlined in this manual when operating over obstacles See page 33 Always be careful of skidding or sliding On slippery surfaces such as ice travel slowly and exercise caution to reduce the chance of skidding or...

Page 15: ...fication section of this manual or the Manufacturer s Label on the vehicle for model specific information When determining the weight you will be adding to your vehicle and to ensure you do not exceed the maximum payload capacity include the following operator body weight passenger body weight weight of all occupants apparel and items in or on apparel weight of any options or accessories and their...

Page 16: ...V 8 Z87 1 or CE Never operate or ride in this vehicle while barefoot or while wearing sandals or tennis shoes Operating Without Instruction Operating this vehicle without proper instruction increases the risk of an accident The operator must understand how to operate the vehicle properly in different situations and on different types of terrain All operators must read and understand the Owner s Ma...

Page 17: ...cribed in this owner s manual See page 51 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 ...

Page 18: ...ain hidden rocks bumps or holes that could cause loss of control or rollover Travel slowly and use extra caution when operating on unfamiliar terrain Always be alert to changing terrain conditions Unauthorized Use of the Vehicle Leaving the keys in the vehicle can lead to unauthorized use of the vehicle by someone under the age of 16 without a drivers license or without proper training This could ...

Page 19: ...excessively rough slippery or loose terrain could cause loss of traction loss of control accident or rollover Do not operate on excessively slippery surfaces Always slow down and use additional caution when operating on slippery surfaces Skidding or sliding due to loss of traction can cause loss of control or rollover if tires regain traction unexpectedly Always follow proper procedures for operat...

Page 20: ...18 FEATURES AND CONTROLS Component Locations Console Hip Bar Cargo Box Headlights Front Bumper Brush Guard Receiver Hitch Tailgate Taillight ...

Page 21: ...9 FEATURES AND CONTROLS Console Instrument Cluster MODE Button Gear Selector Cup Holder Ignition Light Switch Brake Pedal Throttle Pedal Storage Compartment Auxiliary Outlet Storage Tray Dump Box Switch ...

Page 22: ...M1400 High gear is intended for use on hard packed surfaces with light loads Whenever the vehicle is left unattended always place the transmission in PARK To change gears stop the vehicle and with the engine idling move the lever to the desired gear Do not attempt to shift gears with engine speed above idle or while the vehicle is moving Tip Maintaining shift linkage adjustment is important to ass...

Page 23: ...sed Always check that the throttle pedal returns normally before starting the engine This vehicle is equipped with a throttle release switch which is designed to reduce the risk of a frozen or stuck throttle If the throttle cable should stick in an open position when the operator releases the throttle pedal engine speed will be limited and power to the rear wheels will be reduced Trailer Hitch Bra...

Page 24: ...ect the OPS if it ever becomes damaged in any way No device can assure occupant protection in the event of a rollover Always follow all safe operating practices outlined in this manual to avoid vehicle rollover WARNING Vehicle rollover could cause severe injury or death Always avoid operating in a manner that could result in vehicle rollover Extreme Use Battery An optional extreme use battery may ...

Page 25: ...will self tighten 4 To release the seat belt press the square red button in the buckle s center Seat Belt Inspection Inspect all seat belts for proper operation before each use of the vehicle 1 Push the latch plate into the buckle until it clicks The latch plate must slide smoothly into the buckle A click indicates that it s securely latched 2 Push the red release latch in the middle of the buckle...

Page 26: ... If the indicator flashes the overheating condition remains and the system will automatically reduce engine power Neutral This lamp illuminates when the transmission is in neutral and the ignition key is in the ON position High Beam This lamp illuminates when the headlamp switch is set to high beam Helmet Seat Belt The lamp is a reminder to the operator to ensure all riders are wearing personal pr...

Page 27: ...ivated All segments including the fuel icon will flash Refuel immediately Tip If the fuel icon fails to display an open or short circuit has occurred in the fuel sensor circuit Your dealer can assist 3 Information Display Area This area displays odometer trip meter engine hour meter and programmable service hour interval 4 Under Over Voltage This warning usually indicates that the vehicle is opera...

Page 28: ...splay option 5 Repeat the procedure to change remaining display settings Clock Mode Tip The clock must be reset any time the battery has been disconnected or discharged 1 Turn the key to the ON position Use the MODE button to toggle to the odometer dis play 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 ...

Page 29: ...ime the engine is started When this feature is enabled it provides a convenient reminder to perform routine maintenance The service interval is programmed at 50 hours at the factory Use the following procedure to change the service interval 1 Press the MODE button until remaining service hours display 2 Press and hold the MODE button 3 When the service hours flash press and release the MODE button...

Page 30: ...uminates retrieve the error codes from the display 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 hold the MODE button to enter the diagnostics code menu 3 Record the three numbers displayed in the gear position clock and odometer displays 4 Press the MODE button to advance to the next error code 5 Press and ho...

Page 31: ...on page 15 2 Check the oil level See page 55 Add the recommended oil as needed to maintain the oil level in the normal safe operating range 3 Drive slowly at first Select an open area that allows room to familiarize yourself with vehicle operation and handling 4 Vary throttle positions Do not operate at sustained idle 5 Perform regular checks on fluid levels controls and areas outlined on the dail...

Page 32: ... roll when in PARK Ensure PARK light illuminates Front suspension Inspect lubricate if necessary 54 Rear suspension Inspect lubricate if necessary 54 Steering Ensure free operation 69 Tires Inspect condition and pressure 10 70 Wheels fasteners Inspect ensure fastener tightness 70 Frame nuts bolts fasteners Inspect ensure tightness Fuel and oil Ensure proper levels 55 Coolant level Ensure proper le...

Page 33: ...the brake pedal and gradually push the throttle toward the floor to begin driving 7 Drive slowly Practice maneuvering and using the throttle and brakes on level surfaces 8 Do not carry a passenger until you have at least two hours of driving experience with this vehicle Never carry more than one passenger in this vehicle Never allow a passenger to ride in the cargo box 9 To stop the vehicle releas...

Page 34: ...t or injury to a passenger 8 Vehicle handling may change with a passenger and or cargo on board Allow more time and distance for braking 9 Always follow all operating guidelines as outlined on safety labels and in this manual Driving On Slippery Surfaces Skidding or sliding can cause loss of control or rollover if tires regain traction unexpectedly When operating on slippery surfaces such as ice o...

Page 35: ...ds such as logs rocks and low hanging branches 3 Travel slowly and use extra caution when operating on unfamiliar terrain Not all obsta cles are immediately visible 4 Avoid operating over large obstacles such as large rocks and fallen trees If unavoidable use extreme caution and operate slowly 5 Always have all passengers dismount and move away from the vehicle before operating over an obstacle th...

Page 36: ...ate of speed and throttle opening Never open the throttle suddenly 6 Never go over the crest of a hill at high speed An obstacle a sharp drop or another vehicle or person could be on the other side of the hill Driving Downhill When driving downhill follow these precautions 1 Avoid excessively steep hills 2 Drive straight downhill Avoid descending a hill at an angle which would cause the vehicle to...

Page 37: ...stacles or people behind the vehicle Always inspect left and right fields of vision before backing 2 Always avoid backing downhill 3 Back slowly 4 Apply the brakes lightly for stopping 5 Avoid turning at sharp angles 6 Never open the throttle suddenly Parking the Vehicle 1 Apply the brakes Stop the vehicle on a level surface 2 When parking inside a garage or other structure be sure that the struct...

Page 38: ...tacles 4 Avoid operating through deep or fast flowing water WARNING The large tires on your M1400 may cause the vehicle to float in deep or fast flowing water which could result in loss of control and lead to serious injury or death Never cross deep or fast flowing water with your M1400 5 After leaving water always dry the brakes by applying light pressure to the pedal repeat edly until braking ac...

Page 39: ...D 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 PROBLEMS Use extreme caution when applying brakes with a loaded vehicle Avoid terrain or situations that may require backing downhill USE EXTREME C...

Page 40: ... other location or you may lose control of the vehicle 5 Never tow a trailer on a grade steeper than 15 Belt Life To extend belt life use the lowest gear possible when hauling or towing heavy loads Towing the Vehicle Follow these procedures when towing the vehicle 1 Place the gear selector in neutral 2 Turn the key off 3 Always follow these precautions when towing this vehicle Do not operate faste...

Page 41: ...lease the switch after the cargo has dumped or when the box reaches the fully elevated position indicated by a ratcheting sound Press and hold the bottom of the dump box switch to lower the cargo box Release the switch when the box is fully seated on the frame indicated by a ratcheting sound Using Release Lever Stand clear of the cargo box and pull the release lever Lift the front of the cargo box...

Page 42: ...K 2 Remove the key to prevent loss 3 Secure the seat hood and tailgate latches Ensure that the seats are attached correctly and are not loose WARNING Cargo and other loose vehicle parts may fly off while transporting this vehicle Secure or remove all cargo and inspect the unit for loose parts prior to transport 4 Always tie the frame of the vehicle to the transporting unit securely with suitable s...

Page 43: ...le winch winch cable and load clear of people especially children and distractions while operating the winch 8 Always turn the vehicle ignition power OFF when it and the winch are not being used 9 Always be sure that at least five 5 full turns of winch cable are wrapped around the winch drum at all times The friction provided by this wrapped cable allows the drum to pull on the winch cable and mov...

Page 44: ...un through your hands even if wearing heavy gloves 18 Never release the clutch on the winch when the winch cable is under load 19 Never use the winch for lifting or transporting people 20 Never use the winch to hoist or suspend a vertical load 21 Never immerse or submerse your winch in water Your dealer can provide service on your winch if this occurs 22 Always inspect your winch and winch cable b...

Page 45: ...g 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 help when this happens 1 Always inspect the vehicle winch winch cable and winch controls for any signs of damage or parts in need of repair or replacement before each use Pay particular attention to...

Page 46: ...nt parts available at your authorized dealer C If possible keep the winch cable aligned with the centerline of the winching vehicle This will help the spooling of the winch cable and reduce the load on the fairlead D If freeing a stuck vehicle by attaching to a tree use an item such as a tow strap to avoid damaging the tree during winch operation Sharp cables and chains can damage and even kill tr...

Page 47: ...e moving when using the winch is when that vehicle itself is stuck The winch equipped vehicle should NEVER be in motion to shock load the winch cable in an attempt to move a second stuck vehicle See the Shock Loading section on page 48 For your safety always follow these guidelines when winching a vehicle free A Release the winch clutch and spool out the necessary length of winch cable B Align the...

Page 48: ... 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 winch B Feed out the winch cable that is unevenly bunched up in one area C Re engage the winch clutch D Have an assistant pull the winch cable tightly with about 100 lbs 45 kg of tension using the hook...

Page 49: ...le 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 right Even though it may look usable the cable has been permanently and severely damaged It can no longer transmit the load that it could prior to kinking Promptly discontinue use of a winch cable in thi...

Page 50: ...ing This puts extra load on the winch winch cable and generates excessive heat from the motor This is a form of shock loading 3 Never tow a vehicle or other object with your winch Towing an object with a winch produces shock loading of the cable even when towing at slow speeds Towing from a winch also positions the towing force high on the vehicle This can cause instability of the vehicle and poss...

Page 51: ...al activation of the winch 4 For your safety always replace POLARIS winch parts including the cable with genuine POLARIS replacement parts available at your authorized dealer 5 Some winch models use wire rope as the winch cable Other winches use a specially designed synthetic rope as the winch cable 6 Never replace a synthetic rope winch cable with a consumer grade polymer rope such as can be purc...

Page 52: ...ase system Blow by gases are forced back to the combustion chamber by the intake system All exhaust gases exit through the exhaust system Exhaust Emission Control System Exhaust emissions are controlled by engine design An electronic fuel injection EFI system controls fuel delivery The engine and EFI components are set at the factory for optimal performance and are not adjustable The emissions lab...

Page 53: ...sions related service Record maintenance and service in the Maintenance Log beginning on page 93 Tip Service and adjustments are important for proper vehicle operation If you re not familiar with safe service and adjustment procedures a qualified dealer can perform these operations Vehicles subjected to heavy or severe use patterns must be inspected and serviced more frequently Severe Use Definiti...

Page 54: ... filter pre filter Daily Inspect clean often replace as needed Coolant Daily Check level Ź Air filter Weekly Inspect replace as needed Fuel System 25 H Monthly Inspect cycle key to pressurize fuel pump check lines and fittings for leaks and abrasion Ź Front Gearcase oil if equipped 25 H 1 M Perform a break in oil level check Ź Middle Gearcase oil if equipped 25 H 1 M Perform a break in oil level c...

Page 55: ... 6 M Inspect level change yearly Ź Middle Gearcase oil if equipped 100 H 6 M Inspect level change yearly Ź Rear gearcase oil if equipped 100 H 6 M Inspect level change yearly Ź Transmission oil 100 H 12 M 1000 1600 Change fluid D Fuel system 100 H 12 M 1000 1600 Check for leaks at tank cap lines pump throttle body replace lines every 2 years Ź Radiator if applicable 100 H 12 M Inspect clean extern...

Page 56: ...ms not listed in the chart should be lubricated at the general lubrication interval Item Lube Method Engine Oil PS 4 5W 50 4 Cycle Oil See page 55 Brake Fluid DOT 4 Brake Fluid See page 68 Main Gearcase Oil Transmission AGL Gearcase Lubricant Transmission Fluid See page 58 Front Gearcase Oil if equipped Demand Drive Fluid See page 59 Front Prop Shaft Yoke if equipped U Joint Grease Locate fittings...

Page 57: ...il level and to add oil An additional oil fill hole is located at the top of the engine Add oil through either the dipstick hole or the upper fill hole Access the upper fill hole cap through the cargo box access panel 1 Position the vehicle on a level surface 2 Place the transmission in PARK 3 Always clean away all dirt and debris from the dipstick area before removing the dipstick Remove the dips...

Page 58: ... to contact skin 4 Place a drain pan beneath engine crankcase and remove the drain plug 5 Allow the oil to drain completely 6 Install a new sealing washer on the drain plug Tip The sealing surfaces on drain plug and crankcase should be clean and free of burrs nicks or scratches 7 Reinstall the drain plug Torque to 11 13 ft lbs 14 5 17 5 Nm 8 Using a clean dry cloth clean the oil filter cover on th...

Page 59: ... cover and o ring Torque the screws to 88 in lbs 10 Nm 15 Fill the sump with 1 75 quarts 1 65 l of the recommended oil 16 Reinstall the upper fill cap if removed and tighten the dipstick 17 Make sure the transmission is in PARK Apply the brakes 18 Start the engine Allow it to idle for one to two minutes 19 Stop the engine Inspect for leaks 20 Re check the oil level on the dipstick and add oil as n...

Page 60: ...not overfill 5 Reinstall the fill plug Torque to specification Fluid Change The drain plug is located on the bottom of the gearcase Access the drain plug through the hole in the skid plate 1 Remove the fill plug 2 Place a drain pan under the drain plug 3 Remove the drain plug Allow the fluid to drain completely 4 Clean and reinstall the drain plug Torque to specification 5 Add the recommended flui...

Page 61: ...ide of the front gearcase 1 Position the vehicle on a level surface 2 Remove the fill plug Check the oil level 3 Add the recommended oil as needed 4 Reinstall the fill plug Torque to specification Oil Change 1 Support the vehicle securely with a jackstand 2 Remove the front tire on the driver s side 3 Remove the fill plug 4 Place a drain pan under the drain plug on the bottom right hand side 5 Rem...

Page 62: ...rgo box to access the spark plugs 2 Remove the spark plug cap Using the spark plug wrench provided in the tool kit remove the plug by rotating it counter clockwise 3 Reverse the procedure for spark plug installation 4 Torque to specification Normal Plug The normal insulator tip is gray tan or light brown There will be few combustion deposits The electrodes are not burned or eroded This indicates t...

Page 63: ...se Do not dilute with water See page 84 for the part numbers of POLARIS products To ensure that the coolant maintains its ability to protect the engine we recommend that the system be completely drained every five 5 years and fresh Antifreeze 50 50 Premix added Any time the cooling system has been drained for maintenance or repair replace the coolant with fresh Antifreeze 50 50 Premix If the recov...

Page 64: ...tervals outlined in the Periodic Maintenance Chart beginning on page 51 Do not obstruct or deflect air flow through the radiator by installing unauthorized accessories in front of the radiator or behind the cooling fan Interference with the radiator air flow can lead to overheating and consequentially engine damage 1 Lift the hood CAUTION Escaping steam can cause burns Never remove the pressure ca...

Page 65: ...RIS products only Do not install it in any other product Always make sure the PVT housing is securely in place during operation Belt Replacement Debris Removal If a belt fails always clean any debris from the clutch air duct and from the clutch and engine compartments when replacing the belt WARNING Failure to remove ALL debris when replacing the belt could result in vehicle damage loss of control...

Page 66: ...s responsible for creating excessive heat that destroys belts wears clutch components and causes outer clutch covers to fail Switch to low range while operating at slower speeds to extend the life of the PVT components belt cover etc 13 To install a belt place one end of the belt over the driving clutch Route the belt over the top of the driven clutch and down into the groove of the clutch to allo...

Page 67: ...ur dealer can assist Vehicle Immersion NOTICE If your vehicle becomes immersed major engine damage can result if the machine is not thoroughly inspected Take the vehicle to your dealer before starting the engine If it s impossible to take your vehicle to a dealer before starting it follow the steps outlined below 1 Move the vehicle to dry land or at the very least to water below the footrests 2 Dr...

Page 68: ... and out of the air box 5 With the filter removed clean the intake boot and air box thoroughly and wipe well with a clean dry cloth NOTICE Dirt or debris in the intake boot could result in severe engine damage Always clean all dirt and debris from the intake boot before installing the filter 6 Reinstall the air filter if clean or install a new air filter if soiled Do not attempt to clean the air f...

Page 69: ...ter Never go under the vehicle while it s inclined Use the following procedure to periodically purge accumulated 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 3 Start the engine 4 Purge accumulated carbon from the system by momentarily revving the engine several times 5 If carbon is expelled cover or plug the...

Page 70: ...1 Position the vehicle on a level surface 2 View the brake fluid level at the reservoir in the driver s side wheel well The level should be between the upper MAX and lower MIN level lines 3 If the fluid level is lower than the upper level line add brake fluid to the upper MAX line 4 Apply the brake forcefully for a few seconds and check for fluid leakage around the fittings Brake Inspection 1 Chec...

Page 71: ...y turn the steering wheel left and right There should be 0 8 1 0 20 25 mm of freeplay at the outer rim of the steering wheel 3 If there is excessive freeplay or strange noises or the steering feels rough or catchy have the steering system inspected by an authorized dealer Spring Adjustment Adjust the rear shock absorber springs by rotating the adjustment cams either clockwise or counter clockwise ...

Page 72: ...ace 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 Wheel Removal 1 Apply the brakes Place the transmission in PARK Turn the key off 2 Loosen the wheel nuts slightly 3 Elevate the side of the vehicle by plac...

Page 73: ...Attach the wheel nuts and washers and finger tighten 3 Carefully lower the vehicle to the ground 4 Torque the wheel nuts to specification Fuses If the engine stops or will not start or if you experience other electrical failures a fuse may need replacement Locate and correct any short circuits that may have caused the blown fuse then replace the fuse The fuse box is located in the electrical compa...

Page 74: ...ing a halogen lamp don t touch the lamp with bare fingers Oil from your skin leaves a residue causing a hot spot that will shorten the life of the lamp Headlight Lamp Replacement 1 Open the hood CAUTION Hot components can cause burns to skin Allow lamps to cool before servicing 2 Unplug the headlamp from the wiring harness Be sure to pull on the connector not on the wiring 3 Turn the lamp counter ...

Page 75: ...8 20 cm below the mark placed on the wall Include the weight of a rider on the seat while performing this step 5 If a headlight needs adjustment access the adjustment screw under the hood or through the wheel well 6 Loosen the screw adjust the headlight and tighten the screw 7 Repeat steps 4 6 until the lamp is properly adjusted Brake Lights When the brake pedal is depressed the brake light comes ...

Page 76: ...a con ventional battery A sealed battery can be identified by its flat covers on the top of the bat tery A conventional battery has six filler caps on the top of the battery Always keep battery terminals and connections free of corrosion If cleaning is necessary remove the corrosion with a stiff wire brush Wash with a solution of one tablespoon baking soda and one cup water Rinse well with tap wat...

Page 77: ...1 Remove the seat to access the battery compartment 2 On conventional batteries remove the battery vent tube 3 Disconnect the black battery cable first Disconnect the red battery cable last 4 Remove the battery hold down strap 5 Lift the battery out of the vehicle Be careful not to tip a conventional battery sideways which could spill electrolyte NOTICE If electrolyte spills immediately wash it of...

Page 78: ... could accumulate in an improperly installed vent tube and cause an explosion resulting in serious injury or death Always ensure that the vent tube is free of obstructions and is securely installed as recommended 4 Coat the terminals with dielectric grease or petroleum jelly 5 Connect and tighten the red cable first Connect and tighten the black cable last 6 Verify that cables are properly routed ...

Page 79: ...voltage WARNING An overheated battery may explode causing severe injury or death Always watch charging times carefully Stop charging if the battery becomes very warm to the touch Allow it to cool before resuming charging For a refresh charge follow all instructions carefully 1 Check the battery voltage with a voltmeter or multimeter A fully charged battery will register 12 8 V or higher If the vol...

Page 80: ...s Avoid the use of harsh cleaners which can scratch the finish Do not use a power washer to clean the vehicle Do not use medium to heavy duty compounds on the finish Always use clean cloths and pads for cleaning and polishing Old or reused cloths and pads may contain dirt particles that will scratch the finish Avoid directing water toward electrical components including batteries wiring and switch...

Page 81: ...erior Make any necessary repairs and clean the vehicle as recommended See page 78 Stabilize the Fuel 1 Fill the fuel tank 2 Add POLARIS Carbon Clean Fuel Treatment or POLARIS Fuel Stabilizer or equivalent fuel treatments or stabilizers Follow the instructions on the container for the recom mended amount Carbon Clean removes water from fuel systems stabilizes fuel and removes carbon deposits from p...

Page 82: ...all plastic squeeze bottle filled with the pre measured amount of oil Do this carefully If you miss the plug holes oil will drain from the spark plug cavities into the hole at the front of the cylinder head and appear to be an oil leak 3 Reinstall the spark plugs Torque to specification See page 60 4 Apply dielectric grease to the inside of each spark plug cap and reinstall the caps onto the plugs...

Page 83: ...te corrosion and oxidation 7 Turn the key off 8 Verify that tire pressure is at specification 9 Block the wheels to prevent rolling 10 Fully charge the batteries Leave the charger connected to maintain a full charge during the storage period or check battery voltage each month during storage and recharge as needed to maintain a full charge If the charger remains connected check it monthly to verif...

Page 84: ...x Inside 51 5 x 41 75 in 130 8 x 106 cm Wheelbase 79 in 200 7 cm Turning Radius GVW Left 175 in 444 5 cm Right 159 in 403 9 cm Turning Radius LVW Left 176 2 in 447 5 cm Right 158 6 in 402 8 cm Fuel Capacity 8 8 gal 33 3 l Engine Oil Capacity 1 75 qts 1 6 l Coolant Capacity 120 oz 3 5 l Load Capacity Cargo Box Capacity 1100 lbs 499 kg Payload Capacity 1450 lbs 658 kg Hitch Towing Capacity 1500 lbs ...

Page 85: ...7F 031 0 7 0 9 mm Lubrication System Wet Sump Cooling Liquid Front suspension Independent Macpherson struts w 5 in 12 5 cm travel Rear suspension Dual A Arm w 6 in 15 cm travel Tire size 23x8 5 12 Tire pressure 32 psi 220 kPa Throttle Body Size 36 mm Ignition System Digital CDI Driving System Type PVT Shift Type Single Lever console Gear Reduction Low 28 84 1 Gear Reduction Reverse 25 83 1 Gear Re...

Page 86: ...877923 Demand Drive Fluid gal 3 8 l 2870465 Pump for Gallon 3 8 l Jug Coolant 2880514 Antifreeze 50 50 Premix qt 95 l 2880513 Antifreeze 50 50 Premix gal 3 8 l Grease Specialized Lubricants 2871312 Grease Gun Kit All Season Grease 2871322 All Season Grease 3 oz 89 ml cartridge 2871423 All Season Grease 14 oz 414 ml cartridge 2876160 ATV Angle Drive Fluid qt 95 l 2872276 ATV Angle Drive Fluid 2 5 g...

Page 87: ...low range and carefully use fast aggressive throt tle application to engage clutch WARNING Excessive throttle may cause loss of control and vehicle roll over Climbing over large objects from a stopped position Shift the transmission to low range and carefully use fast brief aggressive throttle application to engage clutch WARNING Excessive throttle may cause loss of control and vehicle roll over B...

Page 88: ...g Inspect plug and replace if necessary Water or fuel in crankcase Your dealer can assist Low battery voltage Recharge the battery to 12 8 VDC Mechanical failure Your dealer can assist Possible Cause Solution Weak spark from spark plug Inspect clean and or replace spark plug Incorrect spark plug gap or heat range Set gap to specs or replace plug Old or non recommended fuel Replace with fresh recom...

Page 89: ... Low or contaminated fuel Add or change fuel clean the fuel system Low octane fuel Replace with recommended fuel Clogged fuel filter Your dealer can assist Possible Rich Fuel Cause Solution Fuel is very high octane Replace with lower octane fuel Possible Cause Solution Out of fuel Refuel Kinked or plugged fuel vent line Inspect and replace Water is present in fuel Replace with new fuel Fouled or d...

Page 90: ...inal registration and received the customer copy please contact your dealer immediately NO WARRANTY COVERAGE WILL BE ALLOWED UNLESS YOUR VEHICLE IS REGISTERED WITH POLARIS Initial dealer preparation and set up of your vehicle is very important in ensuring trouble free operation Purchasing a machine in the crate or without proper dealer set up will void your warranty coverage Warranty Coverage And ...

Page 91: ...ES AVAILABLE TO ANY PERSON FOR BREACH OF THIS WARRANTY POLARIS SHALL HAVE NO LIABILITY TO ANY PERSON FOR INCIDENTAL CONSEQUENTIAL OR SPECIAL DAMAGES OF ANY DESCRIPTION WHETHER ARISING OUT OF EXPRESS OR IMPLIED WARRANTY OR ANY OTHER CONTRACT NEGLIGENCE OR OTHER TORT OR OTHERWISE THIS EXCLUSION OF CONSEQUENTAL INCIDENTAL AND SPECIAL DAMAGES IS INDEPENDENT FROM AND SHALL SURVIVE ANY FINDING THAT THE ...

Page 92: ...s vary considerably from country to country You may be required to present documentation of your move to POLARIS in order to continue your warranty coverage You may also be required to obtain documentation from POLARIS in order to register your product in your new country You should warranty register your product at a local POLARIS dealer in your new country immediately after you move to continue ...

Page 93: ...cles starts on the date of purchase by original retail purchaser and continues for a period of 500 hours of engine operation 5000 kilometers 3100 miles of vehicle travel or 30 calendar months from the date of purchase whichever comes first The warranty period for ATVs less than 100cc emissions certified vehicles starts on the date of purchase by original retail purchaser and continues for a period...

Page 94: ...imited warranty also does not cover physical damage corrosion or defects caused by fire explosions or other similar causes beyond the control of POLARIS Owners are responsible for performing the scheduled maintenance identified in the owner s manual POLARIS may deny warranty claims for failures that have been caused by the owner s or operator s improper maintenance or use by accidents for which PO...

Page 95: ...93 MAINTENANCE LOG Use the following chart to record periodic maintenance DATE MILES KM OR HOURS TECHNICIAN SERVICE PERFORMED COMMENTS ...

Page 96: ...94 MAINTENANCE LOG DATE MILES KM OR HOURS TECHNICIAN SERVICE PERFORMED COMMENTS ...

Page 97: ...ing Uphill 34 Driving with a Passenger 32 Driving After Driving in Water 65 Drying the Transmission 65 Dumping the Cargo Box 39 E Emissions Limited Warranty 91 92 Engine Break In 29 Engine Fogging 80 Engine Oil 55 57 Equipment Modifications 13 Error Codes Engine 28 Exhaust Cleaning 67 Exhaust Emission Control System 50 Exhaust System Warning 67 Extreme Use Battery 22 Eye Protection 10 F Filter Cle...

Page 98: ...ehicle 79 Pre Ride Inspection 30 Pressure Tire 10 PVT Break In 29 PVT Drying 65 PVT System 64 65 PVT System Operation 63 PVT Warning 63 65 PVT Cleaning Debris 63 64 R Radiator 61 Registration Warranty 88 Removing the Vehicle from Storage 81 Reverse Operation 35 Rider Information Center 25 28 S Safety Gear 10 Safety Glasses 10 Safety Labels 8 10 Safety Shoes 10 Safety Symbols 4 Safety Winch Mainten...

Page 99: ... 65 Transmission System 64 65 Transmission Warning 63 65 Transmission Drying 65 Transporting the Vehicle 40 V Vehicle Identification Numbers 6 Vehicle Immersion 65 W Warning Symbols 4 Warning Transmission Modification 63 65 Washing the Vehicle 78 Weight Capacity 13 Weight Hitch 38 Wheel Installation 71 Wheel Nut Torque 70 Wheel Removal 70 Winch Cable Care 47 Winch Maintenance and Service Safety 49...

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Page 101: ...For your nearest Polaris dealer call 1 800 POLARIS 765 2747 or visit www polaris com Polaris Industries Inc 2100 Highway 55 Medina MN 55340 Part No 9926638 Rev 01 Printed in USA ...

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