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Polaris PRO XD Owner'S Manual Download Page 162

ENGINE DOESN'T TURN OVER

POSSIBLE CAUSE

SOLUTION

Low battery voltage

Recharge the battery

Loose battery connections

Check all connections and tighten

Loose solenoid connections

Check all connections and tighten

Loose electronic control box 
connections

Inspect, clean, reinstall connectors

ENGINE TURNS OVER, FAILS TO START

POSSIBLE CAUSE

SOLUTION

Out of fuel

Refuel

Water is present in fuel

Drain the fuel system and refuel

Old or non-recommended fuel

Replace with fresh recommended fuel

Fouled or defective spark plug

Inspect plug and replace if necessary

No spark to spark plug

Inspect plug and replace if necessary

Water or fuel in crankcase

Your authorized dealer can assist

Low battery voltage

Recharge the battery to 12.8 VDC

Mechanical failure

Your authorized dealer can assist

ENGINE BACKFIRES

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 recommended fuel

Incorrectly installed spark plug 
wires

Your authorized dealer can assist

Mechanical failure

Your authorized dealer can assist

Loose ignition connections

Check all connections and tighten

Water present in fuel

Replace with fresh recommended fuel

160

TROUBLESHOOTING

Summary of Contents for PRO XD

Page 1: ...OWNER S MANUAL For Maintenance and Safety PRO XD 2022...

Page 2: ...e except as necessary service your vehicle in a well ventilated area and wear gloves or wash your hands frequently when servicing your vehicle For more information go to www P65Warnings ca gov passeng...

Page 3: ...2022 Owner s Manual Pro XD Full Size...

Page 4: ...on is based on the latest product information at the time of publication Due to constant improvements in the design and quality of production components some minor discrepancies may result between the...

Page 5: ...the engineering design and development of your POLARIS vehicle For safe and enjoyable operation of your vehicle be sure to follow the instructions and recommendations in this owner s manual Your manu...

Page 6: ...4 WELCOME...

Page 7: ...tion 7 Safety 11 Features and Controls 31 Operation 65 Winch Guide 85 Emission Control Systems 95 Maintenance 97 Specifications 151 POLARIS Products 157 Troubleshooting 159 Warranty 163 Maintenance Lo...

Page 8: ...6...

Page 9: ...UST be at least 16 years of age 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 Never permit a guest to operate this veh...

Page 10: ...NING indicates a hazardous situation which if not avoided COULD result in death or serious injury CAUTION CAUTION indicates a hazardous situation which if not avoided COULD result in minor to moderate...

Page 11: ...nd store it in a safe place Additional pre cut keys for your vehicle can be ordered The engine serial number can be found on a decal applied to the front of the engine crankcase q or stamped into the...

Page 12: ...10...

Page 13: ...pared for operating conditions and wear the appropriate safety gear Department of Transportation DOT approved helmets are required for all riders when operating at 30 MPH or above Approved helmets in...

Page 14: ...ent safety labels are provided by POLARIS at no charge The part number is printed on the label The seat belt drive responsibly warning label the proper use warning label and the payload warning are lo...

Page 15: ...feet in vehicle at all times Reduce speed and use extra caution when carrying passengers Avoid sharp turns or turns while applying heavy throttle Operate slowly in reverse avoid sharp turns or sudden...

Page 16: ...le access collisions with cars and trucks can occur Do not exceed seating capacity 2 occupants PROPER USE WARNING 4 SEAT WARNING Part Number 7300099 Require Proper Use of Your Vehicle Do your part to...

Page 17: ...ph 860 lbs 376 kg Full Size Gas 25 mph 40 kph 1250 lbs 567 kg Full Size Gas Crew 25 mph 40 kph 1250 lbs 567 kg FUEL TRANSPORT WARNING The fuel transport warning label q is located in the cargo box WAR...

Page 18: ...ying cargo Carrying tall off center or unsecured loads will increase your risk of losing control Center and secure loads as low as possible in box Reduce speed and cargo on rough or hilly terrain Chec...

Page 19: ...detailed loading information CLUTCH COVER WARNING The clutch cover warning q is located on the clutch cover WARNING Part Number 7182350 Improper service or maintenance of this CVTsystem can result in...

Page 20: ...nly when vehicle is stationary and at idle When vehicle is stopped place gear selector in PARK TRAILER HITCH CAPACITY The trailer hitch capacity label is located on the rear hitch bracket CAUTION Part...

Page 21: ...the instructions in this manual for hauling cargo or pulling a trailer Allow a greater distance for braking Always be sure there are no obstacles or people behind your vehicle when operating in revers...

Page 22: ...e 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 stop the engine before refueling...

Page 23: ...e Owner s Manual and all warning and instruction labels before operating the vehicle AGE RESTRICTIONS This vehicle is an ADULT VEHICLE ONLY NEVER operate this vehicle if you are under age 16 and NEVER...

Page 24: ...perform the Pre Ride Inspection outlined in the Operation chapter before each use of your vehicle to make sure it s in safe operating condition Always follow the inspection and maintenance procedures...

Page 25: ...pressures are listed in the specifications section of this manual and on a label on the vehicle Always follow these guidelines UNDER ANY OF THESE CONDITIONS DO ALL OF THESE STEPS Operator and or carg...

Page 26: ...eeds IMPROPER HILL CLIMBING CAUTION Improper hill climbing could cause loss of control or rollover Use extreme caution when operating on hills Always follow proper procedures for hill climbing as desc...

Page 27: ...traight downhill while applying light brake pressure to control speed OPERATING IN UNFAMILIAR TERRAIN CAUTION Failure to use extra caution when operating on unfamiliar terrain could result in an accid...

Page 28: ...perating over obstacles could cause loss of control or rollover Before operating in a new area check for obstacles Avoid operating over large obstacles such as large rocks and fallen trees Always foll...

Page 29: ...ing but not limited to seat belts rollover protection devices brakes throttle and steering systems IMPROPER CARGO LOADING Overloading the vehicle or carrying cargo improperly may cause changes in stab...

Page 30: ...and muddy conditions Promptly remove any grass debris or foreign matter clinging to the vehicle and pay particular attention to the exhaust system area EXPOSURE TO EXHAUST CAUTION Engine exhaust fume...

Page 31: ...d if any non POLARIS approved equipment and or modifications have been added to the vehicle that increase speed or power The addition of certain accessories including but not limited to mowers blades...

Page 32: ...30...

Page 33: ...COMPONENT LOCATIONS q Console w Headlights e Radiator r Front Bumper Brush Guard t Muffler Spark Arrester y Receiver Hitch u CV Boot Rear Caliper i ROPS Cab Frame o Cargo Box a Tailgate s Fuel Cap 31...

Page 34: ...ch t Gear Selector Shifter y AWD Switch u USB Charging Outlets i Battery Trickle Charging Outlet o Auxiliary Outlet a Storage Compartment USB OUTLETS The USB outlets can be used to power accessories l...

Page 35: ...rom moisture AUXILIARY OUTLET The auxiliary outlet can be used to power standard 12V accessories like a cell phone charger or a power inverter up to 120 watts Crew models have a second auxiliary outle...

Page 36: ...E 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 s...

Page 37: ...rcuits are on Electrical equipment can be used START Turn the key to the START position to engage the electric starter The key returns to the ON position when released LIGHT SWITCH The ignition switch...

Page 38: ...ode unlocked differential power In Turf Mode the rear drive wheels operate independently 1WD depending on tire traction This mode of operation is well suited to turf driving or when active traction is...

Page 39: ...red whether the vehicle is on or off FOOT PEDALS BRAKE PEDAL Depress the brake pedal q to slow or stop the vehicle Apply the brakes while starting the engine When the brake pedal is depressed the brak...

Page 40: ...ed under the center rear most seat Never use this area for storage Storage compartments are located under all other seats Remove the storage bin under the right rear most passenger seat to access the...

Page 41: ...effort BELT SPIN ALARM The Belt Spin Alarm will sound if the vehicle senses or detects belt spin engine RPM without ground speed The instrument cluster will also scroll the message belt damage occurri...

Page 42: ...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 serio...

Page 43: ...not twisted 2 Push the latch plate into the buckle until it clicks 3 Release the strap it will self tighten 4 To release the seat belt press the square red button in the buckle s center SEAT BELT INS...

Page 44: ...n off any gasoline that splashes on the instrument cluster DISPLAY AREA FUNCTION q Gear Indicator H High Gear L Low Gear N Neutral R Reverse Gear P Park Gear Signal Error or shifter between gears w Di...

Page 45: ...if this warning appears Serious engine damage could result Your authorized POLARIS dealer can assist This lamp will also illuminate if the vehicle is keyed on but not started it will turn off once the...

Page 46: ...r several seconds when the key is turned to the ON position The lamp will keep flashing as long as riders seat belts are not connected High Beam This lamp illuminates when the headlamp switch is set t...

Page 47: ...DISPLAY AREA 1 Pressing the MODE button will change the information displayed in Area 1 q Speed Engine Temperature RPM Ambient Temperature Optional 45 FEATURES AND CONTROLS...

Page 48: ...DISPLAY AREA 2 Toggle the Up Down buttons to change the information displayed in Area 2 w Odometer Engine Temperature Trip 1 Ambient Temperature Optional 46 FEATURES AND CONTROLS...

Page 49: ...Trip 2 RPM Voltage Speed Engine Hours Service Hours 47 FEATURES AND CONTROLS...

Page 50: ...present or stored Units Distance Select MPH or KPH Units Temp Select between F and C Clock Select between 12H or 24H and set time Backlight Color Select between Blue or Red Backlight Level Set backli...

Page 51: ...the image shown above q Press the MODE button w Toggle the Up Down Buttons to change the units MPH or KPH e With the correct unit displayed Press the mode button which will set the unit and return to...

Page 52: ...the image shown above q Press the MODE button w Toggle the Up Down Buttons to change the units F or C e With the correct unit displayed Press the mode button which will set the unit and return to the...

Page 53: ...CLOCK 1 Press and hold the MODE button to enter the Options Menu NOTICE OPTIONS will display on the screen for 3 seconds before showing first menu item 51 FEATURES AND CONTROLS...

Page 54: ...ill set the unit y Toggle the Up Down Buttons to change the units Cycles 10s of Minutes u With the correct unit displayed Press the mode button which will set the unit i Toggle the Up Down Buttons to...

Page 55: ...image shown above q Press the MODE button w Toggle the Up Down Buttons to change the units Blue or Red e With the correct unit displayed Press the mode button which will set the unit and return to the...

Page 56: ...own above q Press the MODE button w Toggle the Up Down Buttons to change the units Increase or De crease Level e With the correct unit displayed Press the mode button which will set the unit and retur...

Page 57: ...to change the units 0 5 10 95 100 e With the correct unit displayed press the MODE button which will set the unit and return you to the Options Menu NOTICE To reset service hours after they have count...

Page 58: ...creen If you forget your PIN your authorized POLARIS dealer can provide assistance 5 If the correct PIN is entered you will enter the Adjustable Speed Limiting menu The screen will read MAX SPEED and...

Page 59: ...mph 40 km h 30 mph 48 km h 35 mph 56 km h or OFF When MAX SPEED is set to OFF the vehicle s max speed is 40 mph 64 km h c When your preferred setting is displayed on the screen press the MODE button...

Page 60: ...across the screen Enter the new 4 digit PIN by using the up and down buttons to change the digits and the MODE button to select each digit c Once you have selected all 4 digits NEW PIN SET will scrol...

Page 61: ...hrough Code s NOTICE This option will only be available if a fault code was set or is active during the current ignition key on cycle Turning off the ignition will clear any save fault codes from the...

Page 62: ...orted to a wire at battery voltage DIAGNOSTIC CODES COMPONENT CONDITION SPN FMI Throttle Position Sensor Voltage Too High 51 3 Voltage Too Low 51 4 Engine Temperature Sensor Voltage Too High 110 3 Vol...

Page 63: ...1 MAG Driver Circuit Short to B 1268 3 Ignition Coil Primary Driver 2 PTO Driver Circuit Short to B 1269 3 Fuel Pump Driver Circuit Driver Circuit Open Grounded 1347 5 Driver Circuit Short to B 1347...

Page 64: ...207 5 Driver Circuit Short to B 520207 3 Driver Circuit Grounded 520207 4 System Power Voltage Too High 168 3 Voltage Too Low 168 4 Throttle Safety Signal Voltage Too High 520194 3 Voltage Too Low 520...

Page 65: ...mal Or Shorted To High Source 168 3 Voltage Below Normal Or Shorted To Low Source 168 4 Engine Speed Data Valid But Above Normal Operational Range Most Severe Level 190 0 Data Erratic Intermittent Or...

Page 66: ...16 EPAS Communications Receive Data Error Data Erratic Intermittent Or Incorrect 520226 2 Condition Exists 520226 31 Position Encoder Error Root Cause Not Known 520228 11 Bad Intelligent Device Or Com...

Page 67: ...ll damage close fitted engine parts and drive components Do not operate at full throttle or high speeds during the first 3 hours of use ENGINE AND DRIVETRAIN BREAK IN 1 Fill the fuel tank with gasolin...

Page 68: ...let it run in an enclosed area 3 Never operate with accessories not approved by POLARIS for use on this vehicle 4 Use caution and drive at reduced speeds in conditions of reduced visibility such as fo...

Page 69: ...wheel when turned lock to lock page 131 Front Rear Suspension Visually inspect for damages to the control arms trailing arms bushings check for leaking shocks Tires Check for proper air pressure in al...

Page 70: ...led to the FULL COLD mark on coolant reservoir if engine is cold inspect hose and radiator for leaks page 115 Chassis Engine Bay Exhaust Remove grass leaves foreign matter and other flammable material...

Page 71: ...g the vehicle STOPPING THE ENGINE For maximum engine life allow the engine to idle without load for 5 minutes This will allow the engine components that operate at high temperatures such as the exhaus...

Page 72: ...gine speed drops near an idle the vehicle has no engine braking 2 Press on the brake pedal evenly and firmly TIP If the throttle pedal and brake pedal are applied simultaneously engine power may be li...

Page 73: ...at the vehicle is in AWD When the AWD switch is on the front gearcase will automatically engage any time the rear wheels lose traction When the rear wheels regain traction the front gearcase will auto...

Page 74: ...r front gearcases locked The following procedure can be used to unlock the front gearcase on those vehicles as well To disengage AWD do the following 1 Stop the vehicle 2 Operate in reverse for at lea...

Page 75: ...ious injury or death One rear wheel may slip and lose traction or may lift up and grab when it touches the ground again Press the bottom of the switch to unlock the differential and allow the rear dri...

Page 76: ...DRIVING WITH A PASSENGER 1 Perform the pre ride inspection 2 Make sure all passengers are at least 12 years of age and tall enough to comfortably and safely sit in a passenger seat with the seat belt...

Page 77: ...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 Correct a skid by turning the steering wheel in...

Page 78: ...aution 3 Avoid crossing the side of a steep hill DRIVING DOWNHILL When driving downhill follow these precautions 1 Avoid excessively steep hills 2 Always descend a hill with the direction selector swi...

Page 79: ...nt before entering 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...

Page 80: ...OBSTACLES Follow these precautions when operating over obstacles 1 Always check for obstacles before operating in a new area 2 Look ahead and learn to read the terrain Be constantly alert for hazards...

Page 81: ...ion in PARK 4 Turn the engine off 5 Slowly release the brake pedal and make sure the transmission is in PARK before exiting the vehicle 6 Remove the ignition switch key to prevent unauthorized use PAR...

Page 82: ...e 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...

Page 83: ...Do not operate the vehicle faster than 10 mph 16 km h when towing 3 Towing a trailer increases braking distance Do not operate the vehicle faster than 10 mph 16 km h when towing 4 Do not tow more tha...

Page 84: ...sitioned evenly or toward the front of the cargo box 4 Release the tailgate by pulling up on the tailgate latch WARNING If the weight distribution on the box is located toward the rear of the box when...

Page 85: ...NING Operating the vehicle while the cargo box is raised could result in serious injury The box could close unexpectedly and cause injury to the driver or passenger The rear tires could also catch the...

Page 86: ...84...

Page 87: ...e winch cable fairlead and hook when operating winch 6 Never attempt to jerk a load attached to the winch with a moving vehicle See the Shock Loading section on page 93 7 Always keep the area around t...

Page 88: ...ds or if the winch stalls during operation stop winching and permit the winch to cool down for 10 minutes before using it again 16 Never touch push pull or straddle the winch cable while winching a lo...

Page 89: ...ing 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 A...

Page 90: ...be released if the winch cable breaks This can result in SEVERE INJURY or DEATH See the Shock Loading section on page 93 Never hook the winch cable back onto itself This will damage the winch cable a...

Page 91: ...Release the winch clutch and pull out the winch cable 7 Pulling out as much cable as possible maximizes the winch s pulling capacity Always be sure that at least five 5 full turns of winch cable are...

Page 92: ...hen winching a vehicle free a Release the winch clutch and spool out the necessary length of winch cable b Align the winch cable as close as possible to the winching vehicle s centerline c Attach the...

Page 93: ...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 winc...

Page 94: ...this cable has already been permanently and severely damaged Promptly discontinue use of a winch cable in this condition A kinked winch cable made of wire rope that has been straightened out is shown...

Page 95: ...tra 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 produc...

Page 96: ...your safety always replace POLARIS winch parts including the cable with genuine POLARIS replacement parts available at your authorized POLARIS dealer or other qualified person 5 Some winch models use...

Page 97: ...uipped with a closed crankcase system Blow by gases are forced back to the combustion chamber by the intake system All exhaust gases exit through the exhaust system EXHAUST EMISSION CONTROL SYSTEM Exh...

Page 98: ...96...

Page 99: ...necessary When inspection reveals the need for replacement parts genuine POLARIS parts are available from your POLARIS dealer Record maintenance and service in the Maintenance Log at the end of the ma...

Page 100: ...25 hours or one month MAINTENANCE INTERVALS The maintenance interval charts list required maintenance and inspection based on vehicle hours miles Each table states a service that corresponds to the ho...

Page 101: ...filter change at first 25 hrs XU Brake Pads Inspect pad wear contact dealer to replace if worn beyond service limit E Fuel System Turn key on to pressurize fuel pump check lines and fittings for leaks...

Page 102: ...Inspect Contact dealer to adjust as needed Steering Inspect for loose components and torn boots contact dealer to replace parts as needed XU Rear Stabilizer Bar Lubricate and inspect bushings XU Radia...

Page 103: ...bricant if needed XU Transmission Lubricant AGL Inspect add lubricant if needed XU Air Filter Air Box Inspect replace filter as needed or yearly Item part of Pre Ride Inspection E Air Intake Ducts Ada...

Page 104: ...ttle Pedal Inspect replace if it sticks E Air Intake Ducts Adapters Engine Breather Inspect ducts for proper sealing and ensure clamps are tight contact dealer for any repairs XU Air Filter Air Box Re...

Page 105: ...components as needed Clean out after operating in mud XU Wiring Inspect for wear routing security inspect connectors subjected to water mud etc D Clutches Drive and Driven Inspect clean replace worn p...

Page 106: ...et 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 Add to proper level on dipstick See pag...

Page 107: ...m the maintenance procedures as outlined in the Periodic Maintenance Chart OIL RECOMMENDATIONS POLARIS recommends the use of POLARIS PS 4 5W 50 4 Cycle Oil or a similar oil Refer to the Specifications...

Page 108: ...as necessary to bring the oil level within the SAFE range on dipstick Do not overfill see NOTE below NOTE A rising oil level between checks during cold weather operation can indicate contaminants such...

Page 109: ...directly under the crankcase 1 Position vehicle on a level surface and place the transmission in PARK 2 Stop the engine and allow it to cool down 3 Clean the area around the crankcase drain plugq CAUT...

Page 110: ...l fill cap Fill engine with recommended engine oil 13 Verify the transmission is still in PARK 14 Start the engine and allow it to idle for 30 seconds 15 Stop the engine and inspect for oil leaks Wait...

Page 111: ...SSION OIL CHECK Always check and change the transmission oil at the intervals outlined in the Periodic Maintenance Chart Maintain the oil level even with the bottom thread of the fill plug hole The fi...

Page 112: ...ck for leaks Discard used fluid properly DEMAND DRIVE FRONT GEARCASE IF EQUIPPED DEMAND DRIVE OIL CHECK Always check and change the demand drive fluid at the intervals outlined in the Periodic Mainten...

Page 113: ...eaks 10 Discard used oil properly GREASE LUBRICATION POINTS There are grease fittings at the rear stabilizer bar bushings and on the front propshaft yokes Apply grease until all traces of water have b...

Page 114: ...BASE CREW 112 MAINTENANCE...

Page 115: ...can result in serious engine damage Always use POLARIS recommended spark plugs or their equivalent SPARK PLUG GAP TORQUE ELECTRODE GAP NEW OR USED PLUG TORQUE 0 03 in 0 85 mm 15 ft lbs 20 N m SPARK P...

Page 116: ...tor tip is gray tan or light brown There will be few combustion deposits The electrodes are not burned or eroded This indicates the proper type and heat range for the engine and the service The tip sh...

Page 117: ...mixed and ready to use Do not dilute with water 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 A...

Page 118: ...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 radiator cap q 3 View the coolant level through the opening...

Page 119: ...a level surface 2 Lift the hood View the coolant level in the overflow bottle q 3 If the coolant level is below the safe operating range lift the hood and locate the overflow bottle lid Remove the ca...

Page 120: ...FUEL LEAK INSPECTION 1 Lift the driver s seat and the box to gain access fuel lines 2 Inspect all fuel lines for leaks cracks and loose connections 118 MAINTENANCE...

Page 121: ...nts The PVTsystem rotates at high speeds creating large amounts of force on clutch components As the owner you have the following responsibilities for your own safety and the safety of others Always f...

Page 122: ...tlet duct screen when replacing a drive belt Remove any debris found in the outlet duct or outlet duct screen To remove the belt do the following 1 Remove the nine fasteners q that retain the outer cl...

Page 123: ...ehicle BELT INSPECTION To inspect the drive belt do the following 1 Inspect belt for hour glassing extreme circular wear in at least one spot and on both sides of the belt Hour glassing occurs when th...

Page 124: ...oop the belt over the drive clutch and over the driven clutch 2 Rotate the driven clutch and walk the belt into the clutch 3 Turn the clutch spreader tool counterclockwise to remove from the driven cl...

Page 125: ...then the bottom half over the suspension NOTE Use care when installing the clutch cover Do not damage cover intake boot or electrical harness 6 Install and torque the outer clutch cover boltsw to spe...

Page 126: ...the moisture and air dry the belt and clutches Do not hold the throttle wide open for more than five 5 seconds 6 Allow the engine RPM to settle to idle speed Apply the brakes Shift the transmission to...

Page 127: ...y least to water below the footrests 2 Dry any water present in the air box Filter replacement is required if water is present 3 Remove the spark plugs Turn the engine over several times using the ele...

Page 128: ...air filter at the intervals outlined in the Periodic Maintenance Chart In extremely dusty conditions air filter replacement will be required more often 1 Locate the air filter on the left side of the...

Page 129: ...lter removal is not needed for inspection only IMPORTANT If the filter has been soaked with fuel or oil it must be replaced DO NOTattempt to clean the air filter 5 Place the air filter into the airbox...

Page 130: ...SPECTION 1 Inspect the intake ducts between the filter and engine for loose connections cracking etc Ensure clamps are tight 2 Inspect the engine breather for loose connections cracking etc Ensure cla...

Page 131: ...treme temperatures Allow components to cool sufficiently before proceeding Do not stand behind or in front of the vehicle while purging the exhaust system Never go under the vehicle while it is inclin...

Page 132: ...ead to early brake fade and the possibility of accident or severe injury Change the brake fluid every two years and any time the fluid becomes contaminated the fluid level is below the minimum or if t...

Page 133: ...for signs of cracks excessive corrosion warping or other damage Clean any grease using an approved brake cleaner or alcohol 5 Inspect the brake disc spline and pad wear surface q for excessive wear Ch...

Page 134: ...f a tear is discovered have the boot replaced by an authorized dealer WHEEL BEARING INSPECTION 1 Elevate front end of machine so front wheels are off the ground 2 Check for any looseness in front whee...

Page 135: ...dealer for service 4 Repeat the procedure for the rear wheels AXLE INSPECTION Inspect inboard and outboard boots on both sides of the vehicle front q and rear w for tears If a tear is discovered have...

Page 136: ...nt which could result in serious injury or death Always replace tires when the tread depth measures 1 8 in 3 mm or less Improper tire inflation or the use of non standard size or type of tires may adv...

Page 137: ...een loosened for maintenance service Do not lubricate the stud 2 Piece Flange Nut Front and Rear 60 ft lbs 81 N m Spindle Nut Front 110 ft lbs 149 N m Hub Retaining Nut Rear 180 ft lbs 244 N m WHEEL R...

Page 138: ...If your model is equipped with power steering frequently clean the areas around and on the power steering unit to allow proper cooling Clean these areas e thoroughly LIGHTS Poor lighting can result in...

Page 139: ...lb counterclockwise and remove it from the headlight housing 5 Install the new bulb into the housing and rotate it clockwise 90 to lock it in place NOTICE Make sure the tab on the bulb locates properl...

Page 140: ...he mark placed on the wall Include the weight of a rider on the seat while performing this step 5 If a headlight needs adjustment locate the adjustment screw at the back of the headlight 6 Loosen the...

Page 141: ...E FEATURE SUPPORTED 30A EPS 20A Accessories 20A Chassis 15A Key Switch 15A Lights 10A Charge Receptacle 10A Drive Mode 10A EFI Engine Controller 10A Fuel Pump 10A Horn labeled Audible 5A Switches BATT...

Page 142: ...e fully charged battery in the battery holder Make sure the positive terminal is toward the driver s side of the vehicle 3 Coat the terminals with dielectric grease or petroleum jelly 4 Connect and ti...

Page 143: ...ng 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 multim...

Page 144: ...5 50 11 5 12 0 volts Needs charge At least 13 hours verify state of charge 0 25 11 5 volts or less Needs charge with desulfating charger At least 20 hours Using constant current charger standard amps...

Page 145: ...o prevent water spots WASHING TIPS Avoid the use of harsh cleaners which can scratch the finish Do not use a power washer to clean the vehicle Do not use medium to heavy duty compounds on the finish A...

Page 146: ...ntain dirt particles that will scratch the finish STORAGE TIPS NOTICE Starting the engine during the storage period will disturb the protective film created by fogging and damage could occur Never sta...

Page 147: ...art TRANSPORTING THE VEHICLE LOADING AND UNLOADING The weight distribution of the cargo loaded onto the trailer is important and will have an impact on how the vehicle handles on the road Ensure the w...

Page 148: ...VEHICLE TYPE TIE DOWN MINIMUM WLL All Vehicles 3 300 lb 1497 kg 146 MAINTENANCE...

Page 149: ...tly and are not loose 7 Secure the fuel cap and doors if equipped WARNING Cargo and other loose vehicle parts may fall off while transporting the vehicle Secure or remove all cargo and inspect the uni...

Page 150: ...cargo CAUTION Always use the provided tie down points Not using the provided vehicle tie down points could lead to premature component failure and or excess wear on the tie down straps WARNING Always...

Page 151: ...TIE DOWN LOCATIONS q Front tie down point w Rear tie down points 149 MAINTENANCE...

Page 152: ...150...

Page 153: ...qt 2 4 L Coolant Capacity 5 8 qt 5 5 L Towing Capacity 2500 lb 1134 kg Hitch Tongue Capacity 250 lb 113 kg Max Cargo Box Load 1250 lb 566 kg Overall Length 126 in 320 cm Overall Width 62 5 in 158 8 cm...

Page 154: ...tion System Digital CDI Lubrication System Wet Sump Driving System Type PVT Shift Type Single Lever H L N R P Gear Reduction Low Front 8 56 1 Rear 25 59 1 Gear Reduction Reverse Front 7 67 1 Rear 22 9...

Page 155: ...Capacity 11 5 gal 43 5 L Engine Oil Capacity 2 5 qt 2 4 L Coolant Capacity 6 6 qt 6 25 L Towing Capacity 2500 lb 1134 kg Hitch Tongue Capacity 250 lb 113 kg Max Cargo Box Load 1250 lb 566 kg Overall L...

Page 156: ...86 cm of travel Rear Suspension Independent w 9 in 22 86 cm of travel Ignition System Digital CDI Lubrication System Wet Sump Driving System Type PVT Shift Type Single Lever H L N R P Gear Reduction...

Page 157: ...PRO XD CREW CAB Brakes Front Rear Foot Activated 4 wheel hydraulic disc Hood Headlight 2 single beam 50W quartz halogen Taillights 10 L E D 28W Brake Light 10 L E D 3 1W 155 SPECIFICATIONS...

Page 158: ...156...

Page 159: ...2878069 Pump for Gallon Jug 1 2870465 Demand Drive 1 qt 0 95 L 12 2877922 2 5 gal 9 5 L 2 2877923 Antifreeze Coolant 1 qt 0 95 L 12 2880514 1 gal 3 8 L 6 2880513 Grease Gun Kit Premium All Season 1 2...

Page 160: ...PRODUCT SIZE QUANTITY QUANTITY PART NUMBER 2 5 gal 9 5 L 2 2872280 DOT 4 Brake Fluid 1 2872189 Loctite 565 Thread Sealant 1 2871956 POLARIS Battery Tender Charger 1 2859044 158 POLARIS PRODUCTS...

Page 161: ...NG Excessive throttle may cause loss of control and vehicle rollover Climbing over large objects from a stopped position Shift the transmission to low range and carefully use fast brief aggressive thr...

Page 162: ...ecessary No spark to spark plug Inspect plug and replace if necessary Water or fuel in crankcase Your authorized dealer can assist Low battery voltage Recharge the battery to 12 8 VDC Mechanical failu...

Page 163: ...fective spark plug wires Your authorized dealer can assist Incorrect spark plug gap or heat range Set gap to specs or replace plug Loose ignition connections Check all connections and tighten Water pr...

Page 164: ...to specs or replace plug Loose ignition connections Check all connections and tighten Low battery voltage Recharge the battery to 12 8 VDC Incorrect fuel Replace with fresh recommended fuel Clogged ai...

Page 165: ...ot extend the original term of the warranty The duration of this warranty may vary by international region based upon local laws and regulations REGISTRATION At the time of sale the Warranty Registrat...

Page 166: ...ingestion contamination improper maintenance modified components use of aftermarket or unapproved components accessories or attachments use of unapproved software or calibration unauthorized repairs o...

Page 167: ...Y 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 O...

Page 168: ...tion from the country of the selling dealer s authorized location as proof of residence Upon residence verification the servicing dealer will be authorized to perform the warranty repair IF YOU MOVE I...

Page 169: ...istered to government officials or military personnel on assignment outside of the country where the product was purchased will continue to be covered by the Limited Warranty Please work with your dea...

Page 170: ...date of purchase whichever comes first This EPA emissions warranty period is extended for at least as long as the standard factory warranty that Polaris provides on the vehicle as a whole The EPA emis...

Page 171: ...OF ANY DESCRIPTION WHETHER ARISING OUT OF EXPRESS OR IMPLIED WARRANTY OR ANY OTHER CONTRACT NEGLIGENCE OR OTHER TORT OR OTHERWISE THIS EXCLUSION OF CONSEQUENTIAL INCIDENTAL AND SPECIAL DAMAGES IS INDE...

Page 172: ...by the manufacturer The California evaporative emissions control system limited warranty statement below applies to your Off Highway Recreational Vehicle in California if the vehicle is equipped with...

Page 173: ...performance of a scheduled maintenance As an owner you are responsible for presenting your OHRV EVAP to a Polaris dealer as soon as a problem exists The warranty repairs should be completed in a reaso...

Page 174: ...172...

Page 175: ...MAINTENANCE LOG MAINTENANCE LOG Use the following chart to record periodic maintenance DATE MILES KM OR HOURS TECHNICIAN SERVICE PERFORMED COMMENTS 173 MAINTENANCE LOG...

Page 176: ...174...

Page 177: ...erior 144 Clutch Cover Warning 17 Cold Weather Operation 69 Component Locations 31 Console 32 Cooling System 115 Crankcase Emission Control System 95 Crossing Hillsides 24 D Demand Change Oil Change 1...

Page 178: ...ntenance 23 Inspect and Lubricate 145 Instrument Cluster Adjustable Speed Limiting 56 Back Light Color 53 Back Light Level 54 Clock 51 Diagnostic Code 59 Display Area 1 45 Display Area 2 46 Indicator...

Page 179: ...er Use Warning 4 seat 14 Pulse Bar 37 PVT Break in Clutches Belt 66 R Radiator and Cooling Fan 115 Radiator Coolant Level 116 Rear Differential System 71 Registration Warranty 163 Removal from Storage...

Page 180: ...cle Identification Numbers 9 Vehicle Immersion 125 Vehicle Tie Down Loading and unloading 145 Minimum Working Load Limit WLL 145 Tie Down Locations 149 W Warning Symbols 8 Warranty Coverage And Exclus...

Page 181: ......

Page 182: ...For your nearest Polaris dealer call 1 800 POLARIS 765 2747 or visit www polaris com Polaris Inc 2100 Highway 55 Medina MN 55340 Part No 9940401 Rev 02 Printed in USA...

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