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Polaris Sportsman 700 EFI X2, Owner'S Manual

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Polaris Sportsman 700 EFI X2 Owner'S Manual Download Page 92

89

MAINTENANCE

Lubrication Guide

Check and lubricate all components at the intervals outlined in the 

Periodic Maintenance Chart beginning on page 85. Items not 

listed in the chart should be lubricated at the General Lubrication 

interval.

NOTE:

The a-arms and upper control arms are lubricated at the factory, and 

no additional lubrication will be needed. However, if these components 

are subjected to severe use, grease zerks have been provided for 

additional lubrication at the user's discretion.

Item

Lube

Capacity at 

Fluid Change

Inspection Procedure

Engine Oil

PS-4 PLUS 

Performance 

Synthetic 2W-50 

2 qt. (1.9 l)

See page 90.

Brake Fluid 

DOT 4 Only

---

See page 42.

Transmission Oil

Polaris AGL Syn-

thetic 

Gearcase Lube

32 oz. (948 ml) See page 98.

Demand Drive 

Fluid

(Front Gearcase)

Demand Drive LT 

Premium Fluid

9.3 oz. (275 ml) See page 99.

ADC Fluid

Polaris ADC Fluid

---

See page 100.

Front Prop Shaft 

Yoke

Polaris Premium 

U-Joint Lube

---

Grease fittings (3 pumps 

maximum) every 500 miles, 

before long periods of stor-

age, or after pressure wash-

ing or submerging.

Front Prop Shaft Yoke

Summary of Contents for Sportsman 700 EFI X2

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Page 3: ...er s manual on the next page If you cannot locate this card or if it has been removed please call 1 800 342 3764 for assistance WARNING The engine exhaust from this product contains chemicals known to the State of California to cause cancer birth defects or other reproductive harm ...

Page 4: ...r safe and enjoyable operation of your vehicle be sure to follow the instructions and recommendations in this owner s manual Your manual contains instructions for minor maintenance but information about major repairs is outlined in the Polaris Service Manual and should be performed only by a Factory Certified Master Service Dealer MSD Technician Your Polaris dealer knows your vehicle best and is i...

Page 5: ...uality of production components some minor discrep ancies may result between the actual vehicle and the information presented in this publi cation Depictions and or procedures in this publication are intended for reference use only No liability can be accepted for omissions or inaccuracies Any reprinting or reuse of the depictions and or procedures contained within whether whole or in part is expr...

Page 6: ...w Your Vehicle 5 Safety 6 Features and Controls 38 Operation 60 Emission Control Systems 84 Maintenance 85 Adjustments 136 Troubleshooting 139 Polaris Products 143 Specifications 144 Warranty 150 Maintenance Log 156 Index 158 ...

Page 7: ...4 ...

Page 8: ...number in the spaces provided Remove the spare key and store it in a safe place An ignition key can be duplicated only by ordering a Polaris key blank using your key number and mating it with one of your existing keys The ignition switch must be replaced if all keys are lost Vehicle Model Number ___________________________________________________ Frame VIN _________________________________________...

Page 9: ...steeper than 15 degrees 15 To prevent flip over on hilly terrain when going up or down use throttle and brakes gradually Never operate this vehicle in mode on irregular terrain including hills and obstacles REVERSE operation can be dangerous even at low speeds Steering becomes difficult To prevent flipover avoid sudden braking or sharp turns Use OVERRIDE for reverse speed limiter with caution To p...

Page 10: ...han one passenger passengers affect balance and steering and increase risk of losing control with a passenger under the age of 12 THE OPERATOR MUST ALWAYS use proper riding techniques to avoid vehicle overturns on hills and rough terrain and in turns avoid paved surfaces pavement may seriously affect handling and control reduce speed and use extra caution at all times when carrying a passenger hav...

Page 11: ...SSENGER NEVER RIDE AFTER USING DRUGS OR ALCOHOL NEVER carry a passenger too small to firmly plant feet on footrests and securely grasp hand holds THE PASSENGER MUST ALWAYS use an approved helmet and protective gear securely grasp hand holds and plant feet firmly on footrests tell operator to slow down or stop if uncomfortable get off and walk if conditions require 7174028 Passenger Safety Warning ...

Page 12: ...CCESSORIES Reduce speed and allow greater distance for braking when carrying cargo Overloading or carrying tall off center or unsecured loads will increase your risk of losing control Loads should be centered carried as low as possible in box and firmly secured to the box For stability on rough or hilly terrain reduce speed and cargo Do not block headlight Be careful if load extends over the side ...

Page 13: ...bined Front Rack and Container Load 90 lbs 41 kg 7174201 Clutch Cover Warning WARNING NO STEP Moving parts hazard under belt clutch guard To prevent serious injury do not operate vehicle with guard removed Do not modify engine or clutch Doing so can cause part failure possible imbalance and excessive engine RPM which can result in serious injury or death 7172563 Clutch Cover Warning Rack Warning B...

Page 14: ...too much throttle is applied Loss of control or forward flipover may result especially in 4X4 AWD See Owner s Manual 7175106 Box Warning WARNING Remove flammable material containers from box before filling WARNING Passengers can be thrown off This can cause serious injury or death Never carry passengers in cargo box Maximum Box Load 400 lbs 181 kg 7173890 ...

Page 15: ...eeds established safety standards Approved helmets in the USA and Canada bear a U S Department of Transportation DOT label Approved helmets in Europe Asia and Oceania bear the ECE 22 05 label The ECE mark consists of a circle surrounding the letter E followed by the distinguishing number of the country which has granted approval The approval number and serial number will also be displayed on the l...

Page 16: ...ersonal Protective Equipment PPE bearing markings such as VESC 8 V 8 Z87 1 or CE Make sure protective eye wear is kept clean Gloves Off road style gloves with knuckle pads are the best for comfort and protection Boots The best footwear is a pair of sturdy over the calf boots with low heels Clothing Always wear long sleeves and long pants to protect arms and legs Riding pants with kneepads and a je...

Page 17: ...s contained in this manual can result in severe injury or death A Polaris ATV is not a toy and can be hazardous to operate This vehicle handles differently than other vehicles such as motorcycles and cars A collision or rollover can occur quickly even during routine maneuvers like turning or driving on hills or over obstacles if you fail to take proper precautions Read and understand your owner s ...

Page 18: ...g procedures You should review this information on a regular basis If you purchased a used Polaris ATV you can take the ATV RiderCoursesm by calling ATV Enrollment Express at 800 887 2887 or by visiting www atvsafety org Purchasers of a used Polaris ATV will be charged for this training A Polaris ATV is an off road vehicle Familiarize yourself with all laws and regulations concerning the operation...

Page 19: ...t symbol on your vehicle or in this manual alerts you to the potential for injury WARNING The safety alert warning indicates a potential hazard that may result in serious injury or death CAUTION The safety alert caution indicates a potential hazard that may result in minor injury or damage to the vehicle CAUTION A caution indicates a situation that may result in damage to the vehicle NOTE A note w...

Page 20: ...Never carry more than one passenger on this 2 up ATV Always make sure the passenger seat lock out is functioning properly before carrying a passenger Never permit a guest to operate the ATV unless the guest has read this manual and all product labels and has completed a certified safety training course Always keep both hands on the handlebars and both feet on the foot rests of the ATV during opera...

Page 21: ...nging terrain conditions Never operate on excessively rough slippery or loose terrain Always follow proper turning procedures as described in this manual Practice turning at low speeds before attempting to turn at faster speeds Do not turn at excessive speeds Always have the ATV inspected by an authorized Polaris dealer if it s been involved in an accident Never operate on hills too steep for the ...

Page 22: ...r roll backwards follow the special pro cedure for braking described in this manual Always dismount on the uphill side or to either side if the ATV is pointed straight uphill Turn the ATV around and remount following the procedure described in this manual Always check for obstacles before operating in a new area Never attempt to operate over large obstacles such as rocks or fallen trees Always fol...

Page 23: ...aintain proper tire pressure Never modify an ATV through improper installation or use of acces sories Never exceed the stated load capacity for your ATV Cargo must be properly distributed and securely attached Reduce speed and follow the instructions in this manual for carrying cargo or towing Allow a greater distance for braking FOR MORE INFORMATION ABOUT ATV SAFETY call the Consumer Product Safe...

Page 24: ...ginal equipment of the vehicle create a substantial safety hazard and increase the risk of bodily injury The warranty on your Polaris ATV is terminated if any equipment has been added to the vehicle or if any modifications have been made to the vehicle that increase its speed or power NOTE The addition of certain accessories including but not limited to mow ers blades tires sprayers or large racks...

Page 25: ...al For more information about the ATV RiderCoursesm contact ATV Enrollment Express at 800 887 2887 or visit www atvsafety org WARNING POTENTIAL HAZARD Failure to follow the age recommendations for this ATV WHAT CAN HAPPEN Severe injury and or death could occur if a child under the minimum age recommendation operates this ATV or rides as a passenger Even though a child may be within the recommended...

Page 26: ...ould fall from the vehicle unexpectedly or may contact moving components both of which can result in severe injury or death HOW TO AVOID THE HAZARD Never allow a passenger to ride in the cargo box WARNING POTENTIAL HAZARD Operating an ATV on paved surfaces including sidewalks paths parking lots and driveways WHAT CAN HAPPEN ATV tires are designed for off road use Operating on paved surfaces may ad...

Page 27: ...roved helmet eye protection and protective clothing WHAT CAN HAPPEN Riding an ATV without an approved helmet increases the risk of a severe head injury or death in the event of an accident Riding without eye protection could result in an accident and could increase the chance of a severe injury in the event of an accident HOW TO AVOID THE HAZARD Always be sure operator and passenger wear an approv...

Page 28: ...ing an ATV could result in an accident causing severe injury or death HOW TO AVOID THE HAZARD Never consume alcohol or drugs before or while operating an ATV WARNING POTENTIAL HAZARD Operating the ATV at excessive speeds WHAT CAN HAPPEN Excessive speed increases the operator s chance of losing control of the ATV which can result in an accident causing severe injury or death HOW TO AVOID THE HAZARD...

Page 29: ...Avoid exhibition driving WARNING POTENTIAL HAZARD Failure to inspect the ATV before operating Failure to properly maintain the ATV WHAT CAN HAPPEN Poor maintenance increases the possibility of an accident or equipment damage HOW TO AVOID THE HAZARD Always inspect your ATV before each use to make sure it s in safe operating condition Always follow the inspection and maintenance procedures and sched...

Page 30: ...ays keep both hands on the handlebars and both feet on the footrests of the ATV during operation A passenger should always be seated in the passenger seat with both feet on the footrests and both hands on the passenger grab handles at all times The passenger should never hold on to the operator WARNING POTENTIAL HAZARD Failure to use extra caution when operating the ATV on unfamiliar terrain WHAT ...

Page 31: ... on excessively rough slippery or loose terrain until you ve learned and practiced the skills necessary to control the ATV on such terrain Always use extra caution on rough slippery or loose terrain WARNING POTENTIAL HAZARD Turning improperly WHAT CAN HAPPEN Improper turns could cause loss of control and lead to a collision or overturn HOW TO AVOID THE HAZARD Always follow proper procedures for tu...

Page 32: ...age 73 Always move the 4X4 switch to ADC 4X4 before ascending or descending a hill See page 49 Always check the terrain carefully before ascending any hill Never climb hills with excessively slippery or loose surfaces Shift body weight uphill A passenger should also shift body weight uphill Never open the throttle suddenly while traveling uphill The ATV could flip over backwards Never go over the ...

Page 33: ... hill or other irregular terrain Always move the 4X4 switch to ADC 4X4 before ascending or descending a hill See pages 39 and 49 Always check the terrain carefully before descending a hill Always descend a hill with the transmission in forward gear Do not descend a hill with the transmission in neutral Shift body weight uphill A passenger should also shift body weight uphill Never travel down a hi...

Page 34: ...n any hill until you ve mastered the turning technique on level ground as described in the owner s manual See page 76 Use extra caution when turning on any hill Do not cross a hillside with a passenger on board Avoid crossing the side of a steep hill When crossing the side of a hill Always follow proper procedures as described in the owner s manual Avoid hills with excessively slippery or loose su...

Page 35: ...left if the vehicle is pointing straight uphill Have a passenger dismount first then the operator may dismount Turn the ATV around and remount following the procedure described in the owner s manual See page 76 If the ATV begins rolling backwards Keep operator and passenger body weight uphill Never apply engine power Never apply the rear brake while rolling backwards Apply the single lever brake g...

Page 36: ...se extreme caution and always follow proper procedures as outlined in the owner s manual Always have a passenger dismount before operating over an obstacle that could cause a fall from the vehicle or vehicle tipover WARNING POTENTIAL HAZARD Skidding or sliding WHAT CAN HAPPEN Skidding or sliding can cause loss of control If the tires regain traction unexpectedly the ATV could overturn HOW TO AVOID...

Page 37: ...our weight carefully avoid sudden movements and maintain a slow and steady forward motion Do not make sudden turns or stops and do not make sudden throttle changes Wet brakes may have reduced stopping ability Always test the brakes after leaving water If necessary apply them several times to let friction dry out the pads WARNING POTENTIAL HAZARD Improperly operating in reverse WHAT CAN HAPPEN The ...

Page 38: ...ed in the owner s manual and on safety decals WARNING POTENTIAL HAZARD Operating the ATV with improper modifications WHAT CAN HAPPEN Improper installation of accessories or modification of the ATV may cause changes in handling which could lead to an accident HOW TO AVOID THE HAZARD Never modify the ATV through improper installation or use of accessories All parts and accessories added to the vehic...

Page 39: ...d and securely attached Reduce speed when carrying cargo or pulling a trailer Allow a greater distance for braking Always follow the instructions in the owner s manual for carrying cargo or pulling a trailer See page 64 Always follow the instructions in the owner s manual for operating with a passenger See page 70 WARNING POTENTIAL HAZARD Operating on frozen bodies of water WHAT CAN HAPPEN Severe ...

Page 40: ...eased risk of overturn and loss of control which could result in severe injury or death Never secure a passenger to the vehicle or to the operator with a belt rope or similar device WARNING Exhaust system components are very hot during and after use of the vehicle Hot components can cause serious burns and fire Do not touch hot exhaust system components Always keep combustible materials away from ...

Page 41: ...ine quickly The engine will not start or run when the switch is off NOTE Both the main switch and the engine stop switch will shut off all electri cal power to the vehicle including lights Main Key Switch Use the main key switch to start the engine See page 63 4X4 Switch Use the 4X4 switch to engage ADC 4X4 4X4 or 2X4 See page 49 WARNING Activating the override switch while the throttle is open ca...

Page 42: ... lights on and off and to change the lights from high beam to low beam The key must be in the ON position and the engine stop switch must be in the RUN position WARNING Operating with the differential unlocked when on sloped uneven or loose terrain could cause loss of control and result in serious injury or death One rear wheel may slip and lose traction or may lift up and grab when it touches the...

Page 43: ...hrottle controls could cause an accident and lead to severe injury or death Never start or operate an ATV with a sticking or improperly operating throttle Always contact your dealer for service if throttle problems arise Failure to check or maintain proper operation of the throttle system can result in an accident if the throttle lever sticks during operation Always check the lever for free moveme...

Page 44: ...ravel and master cylinder fluid level before riding When squeezed the lever should feel firm Any sponginess would indicate a possible fluid leak or low master cylinder fluid level which must be corrected before riding Contact your dealer for proper diagnosis and repairs WARNING Operating the ATV with a spongy brake lever can result in loss of braking which could cause an accident Never operate the...

Page 45: ...luid only See page 143 for the part numbers of Polaris products WARNING An over full master cylinder may cause brake drag or brake lock up which could result in serious injury or death Maintain brake fluid at the recommended level Do not overfill WARNING Never store or use a partial bottle of brake fluid Brake fluid is hygroscopic meaning it rapidly absorbs moisture from the air The moisture cause...

Page 46: ...portant Safeguards The parking brake may relax if left on for a long period of time Always block the wheels to prevent rolling Always block the wheels on the downhill side of the ATV if leaving it parked on a hill Another option is to park the ATV in a sidehill posi tion Never depend on the parking brake alone if the ATV is parked on a hill Always block the wheels to prevent rolling WARNING Operat...

Page 47: ...brake reduce brake pedal pressure to brake the rear wheels with out skidding Brake Fluid Level Check the brake fluid level frequently for the auxiliary brake system The reservoir is located under the seat Maintain the fluid level between the maximum and minimum marks WARNING Aggressively applying the auxiliary brake when backing down a hill may cause rear tipover which could result in serious inju...

Page 48: ... line fuel filter is located under the rubber service cover inside the front box Have your dealer replace the filter after every 200 hours of operation and any time the fuel becomes contaminated with dirt or debris Do not attempt to clean the fuel filter Fuel Tank Cap Remove the fuel tank cap to add fuel to the fuel tank Use either leaded or unleaded gasoline with a minimum pump octane number of 8...

Page 49: ...pe just until the engine rolls past the stroke then stop pulling immediately 3 Allow the recoil rope to rewind into the recoil assembly then pull the rope abruptly and forcefully to start the engine 4 Repeat all steps until the engine starts 5 Make sure the handle is fully seated on the housing CAUTION Extending the recoil starter rope until it stops can cause damage to the recoil assembly Do not ...

Page 50: ...hen the switch is on 4X4 the ATV is in 4X4 and the 4X4 indicator light in the instrument cluster will be on When in 4X4 the demand drive unit will automatically engage any time the rear wheels lose traction When the rear wheels regain traction the demand drive unit will automatically disengage There is no limit to the length of time the vehicle may remain in 4X4 NOTE The override switch allows act...

Page 51: ...f the switch is turned off while the demand drive unit is moving it will not disengage until the rear wheels regain traction Engage the 4X4 switch before getting into conditions where front wheel drive may be needed If the rear wheels are spinning release the throttle before switching to 4X4 CAUTION Switching to 4X4 or ADC 4X4 while the rear wheels are spinning may cause severe drive shaft and gea...

Page 52: ...follow ing conditions occur The 4X4 switch must be in the ADC 4X4 position Vehicle speed must be 15 mph 24 km h or less The throttle must be closed throttle lever released The transmission must be in gear high low or reverse Disengaging Active Descent Control The ADC system will automatically disengage if at least one of the fol lowing conditions occur The 4X4 switch is moved out of the ADC 4X4 po...

Page 53: ...he 1 up position for single rider operation Never carry cargo in the rear box when operating the ATV in the 2 up mode with a passenger Seat Conversion 1 Make sure the cargo box dump lever is securely latched 2 Rotate both operator backrest latches 1 4 turn to release the locks 3 Tilt the backrest slightly forward 4 Pull the passenger backrest upward from the bed of the cargo box Dump Lever Passeng...

Page 54: ...ons 6 Lower the operator backrest to create the passenger seat Two retaining pins under the seat should fit into the two grommets on the seat base 7 Test the passenger seat lock out by attempting to release the cargo box dump lever If the dump lever releases the seat is not secure Repeat the set up procedure NOTE If the lock out is not working properly do not allow a passenger to ride the vehicle ...

Page 55: ...ormation NOTE In addition to showing vehicle speed the speedometer needle flashes when a warning condition exists CAUTION High water pressure may damage ATV components Wash the ATV by hand or with a garden hose using mild soap Certain products including insect repellents and chemicals will damage the speedometer lens and other plastic surfaces Do not use alcohol to clean the instrument cluster Do ...

Page 56: ...Mode Indicator 5 Low Battery and Over Voltage This warning usually indicates that the ATV is operating at an RPM too low to keep the battery charged It may also occur when the engine is at idle and high elec trical load lights cooling fan accessories is applied Drive at a higher RPM or recharge the battery to clear the warning 6 Odometer Tachometer Tripmeter Hour Meter Clock 7 Fuel Gauge The segme...

Page 57: ...reset before each trip To reset the trip meter select the trip meter mode Press and hold the mode button override button until the total changes to 0 NOTE In the Rider Information Center the trip meter display contains a deci mal point but the odometer displays without a decimal point Hour Meter Mode This mode logs the total hours the engine has been in operation Tachometer Mode The engine RPM is ...

Page 58: ... as the display is activated 5 Use the mode button to toggle through the diagnostic screens Clock Screen To reset the clock 1 Enter the diagnostic mode 2 Toggle to the clock screen 3 Press and hold the mode button until the hour display flashes Release the button 4 Press and release the mode button once to advance the setting by one hour Press and hold the mode button to advance the hours quickly ...

Page 59: ...r all major repairs Gear Circuit Diagnostic Screen This screen displays the resistance value in ohms being read at the gear switch input of the gauge This screen is for informational purposes only Please see your dealer for all major repairs Programmable service interval When the hours of engine operation equal the programmed service interval setting the wrench icon will flash for 5 seconds each t...

Page 60: ... button 4 Press and release the mode button once to advance the setting by one hour Press and hold the mode button to advance the hours quickly NOTE If you scroll past the intended number press and hold the button until the hours cycle back to zero 5 When the desired setting is displayed wait until the wrench icon stops flashing The new service interval is now programmed Miles Kilometers toggle Th...

Page 61: ...4 Count the number of times the Check Engine icon flashes Example For the two blink codes 42 and 36 the Check Engine icon will flash 4 times pause then flash 2 times code 42 then pause longer blink 3 times pause and blink 6 times code 36 5 A code 61 will signal the end of the sequence If no blink codes are found only codes 12 and 61 will appear during the sequence NOTE The word WAIt will remain on...

Page 62: ...ic Pressure Manifold Air Pressure Sensor High 47 IAC Stepper Motor Open Load 47 IAC Stepper Motor Short to Ground 51 Injector Circuit Malfunction Cyl 1 Open Load Short to Ground 51 Injector Circuit Malfunction Cyl 1 Shorted Load Short to Battery 52 Injector Circuit Malfunction Cyl 2 Open Load Short to Ground 52 Injector Circuit Malfunction Cyl 2 Shorted Load Short to Battery 55 MIL Circuit Open Lo...

Page 63: ...ed or where gasoline is stored Do not overfill the tank Do not fill the tank neck If gasoline spills on your skin or clothing immediately wash it off with soap and water and change clothing Never start the engine or let it run in an enclosed area Engine exhaust fumes are poisonous and can cause loss of consciousness or death in a short time WARNING The engine exhaust from this product contains che...

Page 64: ...yourself with vehicle operation and handling 4 Vary the throttle positions Do not operate at sustained idle 5 Perform regular checks on fluid levels controls and areas outlined on the daily pre ride inspection checklist See page 62 6 Pull only light loads 7 During the break in period change both the oil and the filter at 20 hours or one month PVT Break in Clutches Belt A proper break in of the clu...

Page 65: ...d pressure 107 Wheels fasteners Inspect ensure fastener tightness 107 108 Frame nuts bolts fasteners Inspect ensure tightness Fuel and oil Ensure proper levels 45 90 Coolant level if applicable Ensure proper level 102 103 Coolant hoses if applicable Inspect for leaks Throttle Ensure proper operation 40 138 Indicator lights switches Ensure operation 38 Engine stop switch Ensure proper operation 38 ...

Page 66: ...sition and wait five seconds before attempting to start again Activate the starter for another five seconds if necessary Repeat this procedure until the engine starts Cold Weather Operation If the ATV is used year round check the oil level frequently A rising oil level could indicate the accumulation of contaminates such as water or excess fuel in the bottom of the crankcase Water in the bottom of...

Page 67: ... may shift and create unstable operating conditions which could result in loss of control of the vehicle Always be sure that the cargo bed is lowered and latched before moving the vehicle USE EXTREME CAUTION when operating with loads extending beyond the rack or cargo bed Stability and maneuverability may be adversely affected causing the machine to overturn BALANCE LOADS proportionally between th...

Page 68: ...n reduce speed and cargo weight to maintain stable driving conditions Do not obstruct the headlight beam with cargo Use low forward gear when hauling or towing heavy cargo to extend belt life 1 Always load the cargo box with the load as far forward as possible 2 Always operate the vehicle with extreme caution whenever hauling or towing loads Balance handling and control may be affected 3 Slow down...

Page 69: ...hen towing Avoid towing on inclines CAUTION Using an improper hitch or exceeding the maximum tongue weight capacity can result in serious damage to the vehicle and will void your ATV warranty Never install a hitch longer than 6 3 4 17 cm Never install automotive accessories on your Polaris ATV Always install Polaris approved or equivalent accessories designed for ATV use 500 EFI 700 800 EFI Maximu...

Page 70: ...ecured 9 Secure the tailgate WARNING If cargo weight is placed toward the rear of the cargo box the load may dump unexpectedly and cause serious injury When loading cargo always position the weight as far forward and as low as possible WARNING Operating with the cargo box in the raised position can cause serious injury and damage to the vehicle The cargo box could close unexpectedly and injure the...

Page 71: ...t side 6 Sit upright with both feet on the footrests and both hands on the handlebars 7 Start the engine and allow it to warm up 8 Shift the transmission into gear 9 Check your surroundings and determine your path of travel 10 Release the parking brake 11 Slowly depress the throttle with your right thumb and begin driving 12 Drive slowly Practice maneuvering and using the throttle and brakes on le...

Page 72: ...on of the turn 4 Keep both feet on the footrests 5 Lean your upper body to the inside of the turn while supporting your weight on the outer footrest NOTE This technique alters the balance of traction between the rear wheels allowing the turn to be made smoothly 6 The same leaning technique should be used for turning in reverse NOTE Practice making turns at slow speeds before attempting to turn at ...

Page 73: ...rm the pre ride inspection See page 62 4 Convert the seat for 2 up riding See page 50 Make sure the passenger seat lock out is function ing properly 5 Lock the parking brake 6 Mount the vehicle from the left side After the operator is seated the passenger should mount the vehicle from the left side Always make sure the brake is engaged to ensure the vehicle remains motionless whenever a passenger ...

Page 74: ...and both hands on the passenger grab handles at all times The passenger should never hold on to the operator 13 Never secure a passenger to the vehicle or to the operator with a belt rope or similar device 14 Make sure the passenger understands the importance of active riding When hill climbing or performing maneuvers a passenger should shift body weight in the same manner in which the driver shif...

Page 75: ...g the handlebars in the direction of the skid and shifting your body weight forward CAUTION Severe damage to drive train may occur if 4X4 is engaged while the wheels are spinning Always allow the rear wheels to stop spinning before engaging 4X4 or engage 4X4 before wheels begin to lose traction WARNING Failure to exercise care when operating on slippery surfaces can result in loss of tire traction...

Page 76: ...action This may include quick dismounting of the vehicle 8 If the vehicle stalls while climbing a hill never back it down the hill Apply the hand brake If a passenger is on board ask the pas senger to dismount Use the K turn to turn around See page 76 WARNING Braking and handling are greatly affected when operating in hilly terrain Improper procedure could cause loss of control or overturn and res...

Page 77: ...he vehicle 4 Lean into the hill transferring your upper body weight toward the hill while keeping your feet on the footrests 5 Steer slightly into the hill to maintain vehicle direction NOTE If the vehicle begins to tip quickly turn the front wheel downhill if possible or dismount on the uphill side immediately WARNING Improperly crossing hills or turning on hills can result in loss of control or ...

Page 78: ... directly downhill 5 Shift body weight uphill 6 Apply the brakes slightly to aid in slowing NOTE Before operating your ATV learn how to use the auxiliary brake for emergency situations if single lever brakes become inoperable WARNING Excessive speed when traveling downhill can cause loss of control and serious injury or death Slow down Applying the brakes too firmly may cause the rear wheels to lo...

Page 79: ...76 OPERATION Turning Around on a Hill K Turn If the vehicle stalls while climbing a hill never back it down the hill Use the K turn to turn around 8 ft 2 4 m ...

Page 80: ...e is pointing straight uphill 5 Staying uphill of the vehicle turn the handlebars full left 6 While holding the brake lever release the parking brake lock and slowly allow the vehicle to roll around to your right until it s point ing across the hill or slightly downward 7 Lock the parking brake Remount the vehicle from the uphill side keeping body weight uphill NOTE A passenger should not remount ...

Page 81: ...trests Follow these procedures when operating through water 1 Determine water depths and current before crossing 2 Choose a crossing where both banks have gradual inclines 3 Proceed slowly avoiding rocks and obstacles 4 After crossing dry the brakes by applying light pressure to the lever until braking action is normal Maximum Depth ...

Page 82: ...d sudden movements and maintain a slow and steady forward motion Do not make sudden turns or stops and do not make sudden throttle changes If your vehicle becomes immersed and it s impossible to take it to a dealer before starting it follow the steps described on page 118 Have the vehicle serviced by your dealer at the first opportunity CAUTION Major engine damage can result if the vehicle is not ...

Page 83: ... large obstacles such as rocks and fallen trees when possible If unavoidable use extreme caution 3 Always have a passenger dismount before operating over an obsta cle that could cause a fall from the vehicle or vehicle tipover WARNING Severe injury or death can result if your vehicle comes in contact with a hidden obstacle Not all obstacles are immediately visible Travel with caution in unfamiliar...

Page 84: ... an Incline Avoid parking on an incline if possible If it s unavoidable follow these precautions 1 Stop the engine 2 Place the transmission in PARK 3 Lock the parking brake 4 Always block the rear wheels on the downhill side ...

Page 85: ...en it s safe to proceed back slowly Do not use the override switch unless additional power is required for vehicle movement Use with caution Avoid backing on inclines and avoid turning at sharp angles CAUTION Excessive throttle operation while in the speed limit mode may cause fuel to build in the exhaust resulting in engine popping and or engine damage Operate the throttle just enough to maintain...

Page 86: ...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 NOTE Your Polaris ATV is equipped with a reverse speed limiter Use the override button with caution as rearward vehicle speed is greatly increased Do not operate at wide open throttle Apply just enough throttle to maintain a desired speed ...

Page 87: ...ted by 43 CFR 8343 Violations are subject to monetary penalties Federal regulations can be viewed online at www gpoaccess gov ecfr Crankcase Emission Control System This engine is equipped with a closed crankcase system Blow by gases are forced back to the combustion chamber by the intake system All exhaust gases exit through the exhaust system Exhaust Emission Control System Exhaust emissions are...

Page 88: ...service and adjustment procedures have a qualified dealer perform these operations Maintenance intervals in the following chart are based upon average riding conditions and an average vehicle speed of approximately 10 miles per hour Vehicles subjected to severe use must be inspected and serviced more frequently Severe Use Definition Frequent immersion in mud water or sand Racing or race style high...

Page 89: ...rvices Item Maintenance Interval whichever comes first Remarks Hours Calendar Miles Km Steering Pre Ride Make adjustments as needed See Pre Ride Checklist on page 62 Front suspension Pre Ride Rear suspension Pre Ride Tires Pre Ride Brake fluid level Pre Ride Brake lever travel Pre Ride Brake system Pre Ride Passenger seat lock out Pre Ride Wheels fasteners Pre Ride Frame fasteners Pre Ride Engine ...

Page 90: ... breather filter if equipped 25 H Monthly 250 400 Inspect clean if needed X General lubrication 50 H 3 M 500 800 Lubricate all fittings pivots cables etc Shift linkage 50 H 6 M 500 800 Inspect lubricate Q Steering 50 H 6 M 500 800 Lubricate X Front suspension 50 H 6 M 500 800 Lubricate X Rear suspension 50 H 6 M 500 800 Lubricate Q E Throttle Cable ETC Switch 50 H 6 M 500 800 Inspect adjust lubric...

Page 91: ... H 12 M 1000 1600 Inspect Exhaust muffler pipe 100 H 12 M 1000 1600 Inspect Q E Spark plug 100 H 12 M 1000 1600 Inspect replace as needed X Wiring 100 H 12 M 1000 1600 Inspect for wear routing security apply dielectric grease to connectors subjected to water mud etc Q Clutches drive and driven 100 H 12 M 1000 1600 Inspect clean replace worn parts Q Front wheel bearings 100 H 12 M 1000 1600 Inspect...

Page 92: ...n provided for additional lubrication at the user s discretion Item Lube Capacity at Fluid Change Inspection Procedure Engine Oil PS 4 PLUS Performance Synthetic 2W 50 2 qt 1 9 l See page 90 Brake Fluid DOT 4 Only See page 42 Transmission Oil Polaris AGL Syn thetic Gearcase Lube 32 oz 948 ml See page 98 Demand Drive Fluid Front Gearcase Demand Drive LT Premium Fluid 9 3 oz 275 ml See page 99 ADC F...

Page 93: ...il may need to be changed more frequently if Polaris oil is not used Always use 2W 50 oil Follow the manufacturer s recommendations for ambient tempera ture operation See page 143 for the part numbers of Polaris products CAUTION Mixing brands or using a non recommended oil may cause serious engine damage Always use the recommended oil Never substitute or mix oil brands ...

Page 94: ...nkcase If the oil level is over the full safe mark change the oil immedi ately 1 Position the vehicle on a level surface 2 Start the engine Allow it to idle for 20 30 seconds Stop the engine 3 Remove the dipstick Wipe it dry with a clean cloth 4 Reinstall the dipstick completely 5 Remove the dipstick and check the oil level Maintain the oil level in the safe range Do not overfill 6 Reinstall the d...

Page 95: ...OTE The dipstick must be inserted completely to keep the angle and depth of the stick consis tent 4 Remove the dipstick and check the oil level Maintain the oil level in the safe range Do not overfill NOTE Due to the dipstick entry angle into the crankcase the oil level will read higher on the bottom side of the dipstick Always read the level on the upper surface of the dipstick 5 After reinstalli...

Page 96: ...n and free of burrs nicks or scratches 8 Reinstall the drain plug Torque to 14 17 ft lbs 19 23 Nm 9 Disconnect the lower oil deliv ery hose and remove the screen fitting from the oil tank Clean the fitting NOTE The fitting threads must be sealed with LOCTITE PST 505 or PTFE seal tape 10 Reinstall the screen fitting and rotate the fitting clockwise a mini mum of 2 1 2 turns into the tank threads Co...

Page 97: ...an additional 1 2 turn 16 Approximately one cup of engine oil will remain in the crankcase To drain remove the drain plug on the lower right side of the crank case NOTE The sealing surfaces on the drain plug and crankcase should be clean and free of burrs nicks or scratches 17 Reinstall the drain plug Torque to 14 ft lbs 19 Nm 18 Remove the dipstick 19 Add two quarts 1 9 l of recommended oil Reins...

Page 98: ...ximately 2 5 cm from the oil tank between the end of the oil tank vent fitting and the vent line s pressure relief slit 2 Start the engine Allow it to idle for 10 20 seconds 3 Remove the vent line clamp If the line is bled properly you should hear a rush of air indicating that the line is properly primed and ready for operation NOTE If you do not hear air the line has not bled Repeat the priming p...

Page 99: ... idle for two to three min utes 3 Stop the engine 4 Clean the area around the drain plug 5 Place a drain pan under the crankcase 6 Remove the drain plug Allow the oil to drain completely 7 Install a new sealing washer on the drain plug NOTE The sealing surfaces on drain plug and crankcase should be clean and free of burrs nicks or scratches 8 Reinstall the drain plug Torque to 20 ft lbs 27 Nm CAUT...

Page 100: ...il Check to make sure the o ring is in good condition 12 Install the new filter and rotate it clockwise by hand until the filter gasket contacts the sealing surface then turn it an additional 1 2 turn 13 Remove the dipstick 14 Add two quarts 1 9 l of recommended oil 15 Place the transmission in PARK 16 Lock the parking brake 17 Start the engine Allow it to idle for one to two minutes 18 Stop the e...

Page 101: ...cant See page 143 for the part numbers of Polaris products The fill plug is located on the left side of the ATV under the rear fender behind the wheel The drain plug is located on the right side of the gearcase on the right side of the ATV behind the wheel well Transmission Oil Level 1 Position the vehicle on a level surface 2 Remove the fill plug 3 Check the oil level Add the recommended oil as n...

Page 102: ... Always check and change the demand drive fluid at the intervals out lined in the Periodic Maintenance Chart beginning on page 85 We rec ommend the use of Demand Drive LT Premium Fluid Use of other fluids may result in improper operation of components See page 143 for the part numbers of Polaris products Maintain the fluid level at the bottom of the fill hole threads See below for capacity The fil...

Page 103: ...recommended fluid See page 99 for capacity Maintain the fluid level at the bottom of the fill hole threads 7 Reinstall the fill plug Torque to 8 10 ft lbs 11 14 Nm 8 Check for leaks 9 Dispose of used fluid properly Active Descent Control ADC Fluid Two fluid levels must be maintained on your vehicle the demand drive fluid and the ADC fluid See page 99 for demand drive fluid mainte nance Check and c...

Page 104: ...equate bleeding and reduced performance of the system 4 Fill the reservoir to the maximum line with fresh ADC fluid 5 Remove the protective caps from the bleeder valves 6 Slowly loosen one of the valves turn counter clockwise and allow fluid and trapped air to flow from the fitting Close the valve when clean fluid begins to flow Repeat this step for the remaining valve IMPORTANT Close the bleeder ...

Page 105: ... is purging itself of trapped air Check the coolant level and maintain as recommended by adding coolant to the recovery bottle Polaris recommends the use of Polaris Premium 60 40 anti freeze cool ant or a 50 50 mixture of high quality aluminum compatible anti freeze coolant and distilled water Polaris Premium 60 40 is already premixed and ready to use Do not dilute with water See page 143 for the ...

Page 106: ...diator Add coolant as needed 1 Open the front box cover and pull open the access door 2 Remove the pressure cap 3 Using a funnel slowly add coolant through the radiator filler neck 4 Reinstall the pressure cap 5 Secure the access door 6 Secure the box cover NOTE Use of a non standard pressure cap will not allow the recovery system to function properly Contact your dealer for the correct replacemen...

Page 107: ...tem in good operating condition Check more often if brakes are used heavily under normal operation 1 Always keep brake fluid at an adequate level See page 42 2 Check the brake system for fluid leaks 3 Check the brakes for excessive travel or spongy feel 4 Check the friction pads for wear damage and looseness Replace brake pads when they are worn to 3 64 1 mm 5 Check the security and surface condit...

Page 108: ...t edge instead of string 4 Measure the distance from the string to the rim at the front 1 and rear 2 of the front rim The rear measurement should be 1 16 1 8 2 3 mm more than the front measurement on each side of the vehicle to obtain the recommended 1 8 to 1 4 3 6 mm toe out alignment 5 Repeat the measurement procedure on the other side of the vehicle NOTE If you discover improper alignment see y...

Page 109: ... side panel near the rear cab With a firm motion pull the panel outward to disengage the side panel from the grommet Pull the panel downward and rearward to remove it 3 When reinstalling side panels align the fasteners and press firmly to secure them Footwell Removal 1 Remove the six screws on the bottom of the footwell 2 Use a flat screwdriver or sidecutters to remove the plastic rivets securing ...

Page 110: ...parking brake 4 Loosen the wheel nuts slightly 5 Elevate the side of the vehicle by placing a suitable stand under the footrest frame 6 Remove the wheel nuts 7 Remove the wheel WARNING Operating your ATV with worn tires improperly inflated tires non standard tires or improperly installed tires will affect vehicle handling and could cause an accident resulting in serious injury or death Maintain pr...

Page 111: ...s to specification Wheel Nut Torque Specifications Check the wheel nut torques occasionally and when they ve been loos ened for service WARNING Improperly installed wheels can adversely affect tire wear and vehicle handling which can result in serious injury or death Always ensure that all nuts are torqued to specification Do not service axle nuts that have a cotter pin installed See your Polaris ...

Page 112: ...type pre filter from the main filter Wash the pre filter in soapy water then rinse and let dry 5 Reinstall the pre filter over the main filter NOTE Install a new main filter if needed 6 Reinstall the filter into the air box and tighten the clamp Do not over tighten the clamp as filter dam age could occur 7 Reinstall the air box cover and the seat Main Filter Pre Filter ...

Page 113: ...Blow gently through the filter in the direction of the arrow to check for clogging Replace a damaged or clogged filter 4 Check the hoses for cracks deterioration abrasion or leaks Replace as needed 5 Reinstall the filter and hose clamps NOTE The filter is effective with the arrow pointing in either direction CAUTION Operation of your vehicle without a breather filter can cause engine damage Always...

Page 114: ... replace ment NOTE Spare fuses are provided in a compartment on the top of the access door 1 Open the front box cover and pull open the access door 2 Remove the suspect fuse from the fuse panel If the fuse is blown install a new fuse with the same amperage 3 Secure the access door 4 Secure the box cover Fuse Panel Fuses 5or6 15 20 20 ...

Page 115: ...nnect the speedometer harnesses from the speedometer 5 Unplug the headlamp from the wiring harness Be sure to pull on the connector not on the wiring 6 Turn the lamp counterclockwise to remove it 7 Apply dielectric grease to the socket and install the new lamp NOTE Make sure the tab on the lamp locates properly in the housing 8 Reassemble the pod WARNING Poor lighting while driving can result in s...

Page 116: ...n the headlight switch to high beam 4 Observe the headlight aim on the wall The most intense part of the headlight beam should be two inches 5 cm below the mark on the wall NOTE Include rider weight on the seat when measuring 5 The adjustment knob is located on the right side of the headlight pod Adjust the beam to the desired position by turning the knob either clockwise or counterclockwise Low B...

Page 117: ...g harness 5 Use a small screwdriver to remove the o rings from the headlight mounting tabs 6 Pull the headlight housing up to release it from the locking tabs 7 Lift the adjusting knob up to remove it from the locking tabs 8 Carefully pull the assembly up and out of the pod 9 Reverse the steps to install the new housing and reassemble the pod NOTE The distance from the head lamp parting line to th...

Page 118: ...adlamp Taillight Brakelight Worklight if equipped Lamp Replacement 1 Open the tailgate 2 Remove the two screws near the tailgate latch 3 Grasp the entire taillight assembly and pull it away from the vehicle 4 Remove the harness connector from the back of the light assem bly 5 Turn the lamp counterclockwise to remove it 6 Apply dielectric grease to the socket and install the new lamp 7 Reinstall th...

Page 119: ...correct color See page 117 1 Rotate the spark plug cap 1 4 turn and pull it off the spark plug 2 Using the special wrench provided in the tool pouch rotate the spark plug counterclockwise to remove it 3 Reverse the procedure for spark plug installation Torque to specifi cation CAUTION Using non recommended spark plugs can result in serious engine damage Always use Polaris recommended spark plugs P...

Page 120: ...be a carbon layer over the entire nose Generally the electrodes are not worn General causes of fouling are excessive oil use of non recommended oil or incorrect throttle body adjustments Recoil Housing 500 EFI Always drain the recoil housing after operating the vehicle in wet condi tions Drain the housing before storing the vehicle Make sure the hous ing is completely dry before reinstalling the d...

Page 121: ...over several times using the electric start 6 Dry the spark plug Reinstall the plug or install a new plug 7 Attempt to start the engine If necessary repeat the drying proce dure 8 Take the ATV to your dealer for service as soon as possible whether you succeed in starting it or not 9 If water has been ingested into the PVT follow the procedure on page 122 for drying out the PVT CAUTION If your vehi...

Page 122: ...the wheels 8 Place the transmission in PARK Lock the parking brake Repeat steps 4 to 6 until no more particles are expelled 9 Stop the engine Allow the arrestor to cool 10 Reinstall the arrestor plug and remove the exhaust outlet cover or plug WARNING Failure to heed the following warnings while servicing the spark arrestor could result in serious injury or death The exhaust system can get extreme...

Page 123: ...itional loads on components The PVT system rotates at high speeds creating large amounts of force on clutch components Extensive engineering and testing has been conducted to ensure the safety of this product However as the owner you have the following responsibilities to make sure this system remains safe Always follow all recommended maintenance procedures See your dealer as outlined in the owne...

Page 124: ... to the system s dependence on engine speed For example when operating at a ground speed of 3 MPH 5 km h in low range the engine speed would be around 3000 RPM This is well above the engagement speed of 1200 1400 RPM However in high range at 3 MPH 5 km h the engine would be running at only 1500 RPM Whenever operating this close to the engagement speed the engine may be running at a speed too low t...

Page 125: ...K 4 Apply varying throttle for 10 15 seconds to expel the moisture and air dry the belt and clutches NOTE Do not hold the throttle wide open for more than 10 seconds 5 Allow the engine RPM to settle to idle speed then shift the trans mission to the lowest available range 6 Test for belt slippage If the belt slips repeat the process 7 Take the vehicle to your dealer for service as soon as possible ...

Page 126: ...th clean shop towels Coat the termi nals with dielectric grease or petroleum jelly Be careful not to allow cleaning solution or tap water into a conventional battery WARNING Battery electrolyte is poisonous It contains sulfuric acid Serious burns can result from contact with skin eyes or clothing Antidote External Flush with water Internal Drink large quantities of water or milk Follow with milk o...

Page 127: ...reful not to tip a conventional battery sideways which could spill electrolyte WARNING Improperly connecting or disconnecting battery cables can result in an explosion and cause serious injury or death When removing the battery always disconnect the negative black cable first When reinstalling the battery always connect the negative black cable last CAUTION If electrolyte spills immediately wash i...

Page 128: ...urely installed Route the tube away from the frame and vehicle body to prevent con tact with electrolyte 4 On conventional batteries coat the terminals with dielectric grease or petroleum jelly 5 Connect and tighten the red positive cable first 6 Connect and tighten the black negative cable last 7 Install the battery cover 8 Tighten the battery hold down bolt 9 Verify that cables are properly rout...

Page 129: ...can be maintained by using a Polaris Battery Tender charger or by charging about once a month to make up for normal self discharge Battery Tender can be left connected during the storage period and will automatically charge the battery if the voltage drops below a pre determined point See page 143 for the part numbers of Polaris products Battery Fluid Conventional Battery A poorly maintained batte...

Page 130: ...e sealing strip off or add any other fluid to this battery The single most important thing about maintaining a sealed battery is to keep it fully charged Since the battery is sealed and the sealing strip cannot be removed you must use a voltmeter or multimeter to measure DC voltage For a refresh charge follow all instructions carefully 1 Check the battery voltage with a voltmeter or multimeter A f...

Page 131: ...standard amps specified on top of battery 100 12 8 13 0 volts None check at 3 mos from date of manufacture None required 75 100 12 5 12 8 volts May need slight charge if no charge given check in 3 months 3 6 hours 50 75 12 0 12 5 volts Needs charge 5 11 hours 25 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...

Page 132: ...ith a chamois to prevent water spots Washing Tips Avoid the use of harsh cleaners which can scratch the finish Do not use a power washer to clean the vehicle Do not use medium to heavy duty compounds on the finish Always use clean cloths and pads for cleaning and polishing Old or reused cloths and pads may contain dirt particles that will scratch the finish CAUTION High water pressure may damage c...

Page 133: ...ontact your Polaris dealer for free replacement Grease all zerk fittings immediately after washing Allow the engine to run for a while to evaporate any water that may have entered the engine or exhaust system Polishing the Vehicle Polaris recommends the use of common household aerosol furniture polish for polishing the finish on your Polaris vehicle Follow the instructions on the container Polishi...

Page 134: ...ent Never use abrasive cleaners on plated or painted surfaces 2 Rinse well with clear water Soap detergents salt dirt mud and other elements can cause corrosion 3 Polish the clean chrome wheels periodically Use an automotive grade chrome polish 4 Routinely and liberally apply a weather resistant wax to each pol ished chrome wheel Choose a product suitable for chrome finishes Read and follow the pr...

Page 135: ...ves and exhaust sys tems 3 Allow the engine to run for 15 20 minutes to allow the stabilizer to disperse through the entire fuel delivery system Oil and Filter Change the oil and filter See page 93 Air Filter Air Box 1 Inspect and clean or replace the pre cleaner and air filter See page 109 2 Clean the air box 3 Drain the sediment tube 4 Clean or replace the breather filter if equipped See page 11...

Page 136: ...p the engine 2 Remove the spark plug and add 2 3 tablespoons of engine oil To access the plug hole use a section of clear 1 4 hose and a small plastic squeeze bottle filled with the pre measured amount of oil NOTE Do this carefully If you miss the plug hole oil will drain from the spark plug cavity into the hole at the front of the cylinder head and appear to be an oil leak 3 Reinstall the spark p...

Page 137: ...ightly off the ground Be sure the storage area is well ventilated Cover the vehicle with a genuine Polaris cover NOTE Do not use plastic or coated materials They do not allow enough ven tilation to prevent condensation and may promote corrosion and oxi dation Accessories Auxiliary power outlets provide 12 volt power for operating accesso ries Accessory outlets are available for all models Polaris ...

Page 138: ...Lock the parking brake 4 Always secure the seat in the 1 up position to prevent loss during transporting 5 Secure the fuel cap and oil cap 6 Always tie the frame of the ATV to the transporting unit securely with suitable straps or rope Do not attach tie straps to the front A arm bolt pockets 7 Remove the key to prevent loss during transporting ...

Page 139: ...ter are non adjust able Rear Spring The rear shock absorber spring is adjusted by rotating the adjuster either clockwise or counterclockwise to increase or decrease spring tension NOTE Accessory springs are available through your Polaris dealer Adjuster ...

Page 140: ...e left or right 4 Torque the front two bolts to 10 12 ft lbs 14 17 Nm then torque the rear two bolts A gap of up to 1 8 3 mm will remain at the rear of the clamp blocks WARNING Improper adjustment of the handlebars or incorrect torquing of the adjuster block tightening bolts can cause limited steering or loosening of the handlebars resulting in loss of control and possible serious personal injury ...

Page 141: ... handlebar 2 Squeeze the end of the rub ber boot and slide it far enough to expose the end of the inline cable adjuster 3 Loosen the adjuster lock nut 4 Rotate the boot to turn the adjuster until 1 16 to 1 8 1 5 3 mm of freeplay is achieved at the thumb lever NOTE While adjusting freeplay be sure to flip the throttle lever back and forth 5 Tighten the lock nut 6 Squeeze the end of the rub ber boot...

Page 142: ... Shift the transmission to low range and carefully use fast aggressive throttle application to engage clutch WARNING Excessive throttle may cause loss of control and vehicle overturn Climbing over large objects from a stopped position Shift the transmission to low range and carefully use fast brief aggressive throttle application to engage clutch WARNING Excessive throttle may cause loss of contro...

Page 143: ...Fouled or defective spark plug s Inspect plugs and replace if necessary No spark to spark plug Inspect plugs verify stop switch is on Water or fuel in crankcase Immediately see your Polaris dealer Low battery voltage Recharge the battery to 12 8 VDC Mechanical failure See your dealer Possible Cause Solution Weak spark from spark plug Inspect clean and or replace spark plug s Incorrect spark plug g...

Page 144: ...Kinked or plugged fuel tank vent line Inspect and replace Incorrect fuel Replace with recommended fuel Clogged air filter Inspect and clean or replace Reverse speed limiter malfunction See your dealer Electronic throttle control malfunction See your dealer Other mechanical failure See your dealer Possible Lean Fuel Cause Solution Low or contaminated fuel Add or change fuel clean the fuel system Ki...

Page 145: ...nnections and tighten Low battery voltage Recharge the battery to 12 8 VDC Incorrect fuel Replace with fresh recommended fuel Clogged air filter Inspect and clean or replace Reverse speed limiter malfunction See your dealer Electronic throttle control malfunction See your dealer Other mechanical failure See your dealer Overheated engine Clean radiator screen and core clean engine exterior see your...

Page 146: ...l Jug 2876251 Demand Drive LT Premium Fluid 8 oz 237 ml Coolant 2871323 60 40 Coolant gal 3 8 l 2871534 60 40 Coolant qt 95 l Grease Specialized Lubricants 2871312 Grease Gun Kit Premium All Season 2871322 Premium All Season 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 Pre...

Page 147: ... Ground Clearance 11 in 28 cm Minimum Turning Radius 82 in 208 cm unloaded Fuel Capacity 6 gal 22 7 l Engine Oil Capacity 2 qts 1 9 l Coolant Capacity 2 7 qts 2 5 l Demand Drive Fluid Capacity 9 3 oz 275 ml Transmission Oil Capacity 32 oz 948 ml Engine EH50PLE Displacement 499 cc Bore x Stroke 92 x 75 Alternator Output 350 w Compression Ratio 10 2 1 Fuel System Electronic Fuel Injection Ignition S...

Page 148: ... Front Single Control Hydraulic Disc Brakes Rear Single Control Hydraulic Disc Brake Auxiliary Foot Activated Hydraulic Disc Brake Parking Hydraulic lock all wheel Headlight 1 Single Beam on Headlight Pod 50 watt 2 Single Beam on Bumper 37 5 watt Taillights 8 26 watts Brake Light 26 9 watts Instrument Cluster LCD Altitude Shift Weight Drive Clutch Spring Driven Clutch Spring Helix Meters Feet 0 18...

Page 149: ...d Clearance 11 in 28 cm Minimum Turning Radius 82 in 208 cm unloaded Fuel Capacity 6 gal 22 7 l Engine Oil Capacity 2 qts 1 9 l Coolant Capacity 3 4 qts 3 2 l Demand Drive Fluid Capacity 9 3 oz 275 ml Transmission Oil Capacity 32 oz 948 ml Engine EH0680LE Displacement 683 cc Bore x Stroke 80 x 68 Alternator Output 500 Watts 3000 RPM Compression Ratio 9 40 1 Starting System Electric Fuel System Ele...

Page 150: ...25x11 12 5 psi Brakes Front Single Control Hydraulic Disc Brakes Rear Single Control Hydraulic Disc Brake Auxiliary Foot Activated Hydraulic Disc Brake Parking Hydraulic lock all wheel Headlight 1 Single Beam on Headlight Pod 50 watt 2 Single Beam on Bumper 37 5 watt Taillights 8 26 watts Brake Light 26 9 watts Instrument Cluster LCD Altitude Shift Weight Drive Clutch Spring Driven Clutch Spring H...

Page 151: ...nd Clearance 11 in 28 cm Minimum Turning Radius 82 in 208 cm unloaded Fuel Capacity 6 gal 22 7 l Engine Oil Capacity 2 qts 1 9 l Coolant Capacity 3 4 qts 3 2 l Demand Drive Fluid Capacity 9 3 oz 275 ml Transmission Oil Capacity 32 oz 948 ml Engine EH0760LE Displacement 760 cc Bore x Stroke 80x76 Alternator Output 500 Watts 3000 RPM Compression Ratio 10 1 Fuel System Electronic Fuel Injection Ignit...

Page 152: ...25x11 12 5 psi Brakes Front Single Control Hydraulic Disc Brakes Rear Single Control Hydraulic Disc Brake Auxiliary Foot Activated Hydraulic Disc Brake Parking Hydraulic lock all wheel Headlight 1 Single Beam on Headlight Pod 50 watt 2 Single Beam on Bumper 37 5 watt Taillights 8 26 watts Brake Light 26 9 watts Instrument Cluster LCD Altitude Shift Weight Drive Clutch Spring Driven Clutch Spring H...

Page 153: ...olaris dealer REGISTRATION At the time of sale the Warranty Registration Form must be completed by your dealer and submitted to Polaris within ten days Upon receipt of this registration Polaris will record the registration for warranty No verification of registration will be sent to the purchaser as the copy of the Warranty Registration Form will be the warranty entitle ment If you have not signed...

Page 154: ...rosion or defects in parts components or the ATV due to fire explosions or any other cause beyond Polaris control This warranty does not cover the use of unauthorized lubricants chemicals or fuels that are not compatible with the ATV The exclusive remedy for breach of this warranty shall be at Polaris exclusive option repair or replacement of any defective materials or com ponents or products THE ...

Page 155: ...e your original selling dealer however you may use any Polaris Servicing Dealer to perform warranty service Please work with your dealer to resolve any warranty issues Should your dealer require any additional assistance they will contact the appropriate person at Polaris This warranty gives you specific legal rights and you may also have other rights which vary from state to state If any of the a...

Page 156: ...eling within the country where your vehicle was purchased Warranty or Service Bulletin repairs may be requested from any authorized Polaris dealer who sells the same line as your vehicle Outside the Country where your vehicle was purchased If you are traveling temporarily outside the country where your vehicle was purchased you should take your vehicle to an authorized Polaris dealer You must show...

Page 157: ...red outside of the country where it was purchased and you have not followed the procedure set out above your vehicle will no longer be eligible for war ranty or service bulletin coverage of any kind Vehicles registered to Government offi cials or military personnel on assignment outside of the country where the vehicle was purchased will continue to be covered by the basic warranty For questions c...

Page 158: ... replacement of any defective materials components or prod ucts THE REMEDIES SET FORTH IN THIS LIMITED WARRANTY ARE THE ONLY REMEDIES AVAILABLE TO ANY PERSON FOR BREACH OF THIS WAR RANTY POLARIS SHALL HAVE NO LIABILITY TO ANY PERSON FOR INCI DENTAL CONSEQUENTIAL OR SPECIAL DAMAGES OF ANY DESCRIPTION WHETHER ARISING OUT OF EXPRESS OR IMPLIED WAR RANTY OR ANY OTHER CONTRACT NEGLIGENCE OR OTHER TORT ...

Page 159: ... section of your manual to your dealer each time your vehicle is serviced This will provide you and future owners with an accurate log of maintenance and ser vices performed DATE MILES KM OR HOURS TECHNICIAN SERVICE PERFORMED COMMENTS ...

Page 160: ...157 MAINTENANCE LOG DATE MILES KM OR HOURS TECHNICIAN SERVICE PERFORMED COMMENTS ...

Page 161: ...3 Clutching 500 EFI 145 700 EFI 147 800 EFI 149 C Cold Weather Operation 63 Consumer Product Safety 20 Coolant Bottle 102 Coolant Radiator 103 Cooling System 102 103 Corrosion Removal Chrome 131 Crankcase Emission Control System 84 D Demand Drive Capacities 99 Demand Drive Fluid 100 Differential Switch 39 Disengaging Active Descent Control 49 Drive Belt Wear Burn 139 Drivetrain Break In 61 Driving...

Page 162: ...18 Instrument Cluster 52 59 K Key Switch 38 K Turn 76 77 L Lights 112 115 Headlight Housing 114 Headlight Lamp 112 High Beam Adjustment 113 Low Beam Adjustment 113 Lower Headlamp Replacement 115 Taillight Brakelight Worklight 115 Low Range Use 122 Lubrication Guide 89 M Maintenance Chart 85 88 Master Cylinder 42 Mode Switch 38 Modifications 21 N Noise Emission Control System 84 O Oil Engine 90 97 ...

Page 163: ...nt Rear Shock 136 Starting the Engine 63 Steering Assembly 106 Storage 129 134 Storage Tips 132 134 Switches 38 39 4X4 Switch 38 Differential Switch 39 Engine Stop Switch 38 Headlight Switch 39 Main Key Switch 38 Mode Reverse Override Switch 38 Worklight Switch 39 T Taillight Lamp Replacement 115 Throttle Body Adjustment 138 Throttle Cable Freeplay Adjustment 138 Throttle Lever 40 Tires 107 108 Ti...

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