Polaris Sportsman Touring 570 2022 Owner'S Manual Download Page 173

Page: 173 / 198

DIAGNOSTIC CODES

COMPONENT

CONDITION

SPN

FMI

Idle Air Control

Driver Circuit
Open/Grounded

634

Driver Circuit Short
to B+

634

Driver Circuit
Grounded

634

Position Out of
Range

634

Starter Enable
Circuit

Driver Circuit
Open/Grounded

1321

Driver Circuit Short
to B+

1321

Driver Circuit
Grounded

1321

Chassis Relay

Driver Circuit
Open/Grounded

520208

Driver Circuit Short
to B+

520208

Driver Circuit
Grounded

520208

All Wheel Drive
Control

Driver Circuit
Open/Grounded

520207

Driver Circuit Short
to B+

520207

Driver Circuit
Grounded

520207

System Power

Voltage Too High

168

Voltage Too Low

168

Throttle Safety
Signal

Voltage Too High

520194

Voltage Too Low

520194

Signal Out of
Range

520194

171

TROUBLESHOOTING

Summary of Contents for Sportsman Touring 570 2022

Page 1: ...efully It contains important safety information This is an adult vehicle only Operation is prohibited for those under 16 years of age OWNER S MANUAL For Maintenance and Safety Sportsman Touring 570 Sp...

Page 2: ...frequently when servicing your vehicle For more information go to www P65Warnings ca gov passenger vehicle WARNING Read understand and follow all of the instructions and safety precautions in this man...

Page 3: ...2022 Owner s Manual Sportsman X2 570 Sportsman 6x6 570 Sportsman Touring 570 Premium Sportsman Touring 570 Sportsman Touring 570 EPS...

Page 4: ...ered trademark of Cisco Technology Inc Android is a registered trademark of Google LLC Duro is a registered trademark of HWA Fong Rubber USA Inc DBA Duro Tire Wheel Corp AUTOLITE is a registered trade...

Page 5: ...and development of your POLARIS vehicle making it the finest machine we ve ever produced For safe and enjoyable operation of your vehicle be sure to follow the instructions and recommendations in this...

Page 6: ...4 WELCOME...

Page 7: ...ion 7 Safety 11 Features and Controls 43 Operation 75 Winch Guide 97 Emission Control Systems 107 Maintenance 109 Specifications 159 POLARIS Products 167 Troubleshooting 169 Warranty 179 Maintenance L...

Page 8: ...6...

Page 9: ...autions Read this owner s manual Understand all safety warnings precautions and operating procedures before operating a POLARIS ATV Keep this manual with the ATV Never operate an ATV without proper in...

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: ...S 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 The vehicle serial number q can be found stamped on lower frame...

Page 12: ...10...

Page 13: ...rs This training is included in the purchase price of your ATV You were also provided with printed materials that explain safe operating procedures You should review this information on a regular basi...

Page 14: ...ch has granted approval The approval number and serial number will also be displayed on the label EYE PROTECTION Do not depend on eyeglasses or sunglasses for eye protection Whenever riding this POLAR...

Page 15: ...fferent situations and on different types of terrain Beginning and inexperienced operators should complete the recommended safety training before operating this vehicle Never permit a guest to operate...

Page 16: ...spection and maintenance procedures and schedules described in this owner s manual HANDLING GASOLINE Gasoline is highly flammable and explosive under certain conditions Always exercise extreme caution...

Page 17: ...TING ON PAVEMENT This vehicle s tires are designed for off road use only not for use on pavement Operating this vehicle on paved surfaces including sidewalks paths parking lots and driveways may adver...

Page 18: ...rson s feet are not firmly planted on the footrests they could come into contact with the wheels or other moving parts and lead to accident or injury Always keep both hands on the handlebars and both...

Page 19: ...tion for details DESCENDING HILLS IMPROPERLY Improperly descending a hill could cause loss of control or rollover Always follow proper procedures for traveling down hills as described in this owner s...

Page 20: ...ill side of the vehicle or on the 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...

Page 21: ...urn Do not operate on excessively rough slippery or loose terrain until you ve learned and practiced the skills necessary to control the vehicle on such terrain Always use extra caution on rough slipp...

Page 22: ...ollow proper operating procedures as outlined in this manual See the New Operator Driving Procedures section for details Before shifting into reverse gear always check for obstacles or people behind t...

Page 23: ...DAMAGED VEHICLE CAUTION Operating a damaged vehicle can result in an accident After any rollover or other accident have a qualified service dealer inspect the entire machine for possible damage includ...

Page 24: ...you and your cargo together with any other vehicles in your party Always check with local authorities and residents to confirm ice conditions and thickness over your entire route Vehicle operators ass...

Page 25: ...s including trailer surfaces e g trailer hitch trailer tongue trailer walls etc To reduce the risk of inhaling exhaust gases and to avoid risk of burn or injury shut off your engine and allow time for...

Page 26: ...of certain accessories including but not limited to overhead audio speakers may change the forward clearance in the vehicle Polaris recommends selecting a helmet that is compatible with the equipment...

Page 27: ...ns of the labels on the vehicle If an informational or graphic label becomes illegible or comes off contact your POLARIS dealer to purchase a replacement Replacement safety labels are provided by POLA...

Page 28: ...ger seat is securely in place THE OPERATOR MUST ALWAYS use proper riding techniques to avoid vehicle overturns on hills and rough terrain and in turns avoid paved surfaces pavement may seriously affec...

Page 29: ...onditions require WARNING Never operate this ATV on HILLS steeper than 15 degrees To prevent overturn on hilly terrain use throttle and brakes gradually and shift weight uphill REVERSE operation can b...

Page 30: ...n cause loss of control Loss of control can result in severe injury or death Cold tire pressure Front 7 0 psi 48 2 kPa Rear 7 0 psi 48 2 kPa Maximum weight capacity 485 lbs 220 kg NEVER exceed 50 MPH...

Page 31: ...6 570 q General Warning w Age Warning e Discretionary Warning r 4x4 Caution t Override Warning y Clutch Cover Warning u Rack Warning i Passenger Warning o Fuel Transport Warning a Tire Pressure Warnin...

Page 32: ...ger seat is securely in place THE OPERATOR MUST ALWAYS use proper riding techniques to avoid vehicle overturns on hills and rough terrain and in turns avoid paved surfaces pavement may seriously affec...

Page 33: ...onditions require WARNING Never operate this ATV on HILLS steeper than 15 degrees To prevent overturn on hilly terrain use throttle and brakes gradually and shift weight uphill REVERSE operation can b...

Page 34: ...e damage or tipover may result causing severe injury or death Tow only from tow hooks or hitch Maximum Rack Loads Front 90 lbs 41 kg Rear 180 lbs 82 kg FUEL PASSENGER WARNING WARNING Remove flammable...

Page 35: ...re Front 7 0 psi 48 2 kPa Center 10 0 psi 68 9 kPa Rear 10 0 psi 68 9 kPa Maximum weight capacity 1115 lbs 507 kg NEVER exceed 50 MPH 80 km h when rear cargo loads are above 75 lbs 34 kg and or front...

Page 36: ...al Warning w Age Warning e Passenger Safety Warning r 4x4 Caution t Override Warning y Clutch Cover Warning u Rack Warning i Container Passenger Warning o Fuel Transport Warning a Tire Pressure Overlo...

Page 37: ...ger seat is securely in place THE OPERATOR MUST ALWAYS use proper riding techniques to avoid vehicle overturns on hills and rough terrain and in turns avoid paved surfaces pavement may seriously affec...

Page 38: ...onditions require WARNING Never operate this ATV on HILLS steeper than 15 degrees To prevent overturn on hilly terrain use throttle and brakes gradually and shift weight uphill REVERSE operation can b...

Page 39: ...damage or tipover may result causing severe injury or death Tow only from tow hooks or hitch Maximum combined Front Rack and Container Load 90 lbs 41 kg BOX WARNING WARNING Remove flammable material c...

Page 40: ...m weight capacity 705 lbs 320 kg NEVER exceed 50 MPH 80 km h when rear cargo loads are above 75 lbs 34 kg and or front cargo loads are above 37 lbs 17 kg NEVER exceed 50 MPH 80 km h while carrying a p...

Page 41: ...operate this vehicle ALWAYS wear approved helmet goggles and protective clothing NEVER use alcohol or drugs before or while operating NEVER carry more than one passenger This vehicle is approved for...

Page 42: ...ive shaft and clutch damage OVERRIDE ALERT WARNING Improper use of override button can lead to loss of control resulting in severe injury or death Do not activate override while throttle is engaged Al...

Page 43: ...E IN kPa FRONT 48 3 kPa REAR 48 3 kPa RACK ALERT WARNING DO NOT TOW FROM RACK OR BUMPER Vehicle damage or tipover may result causing severe injury or death Tow only from tow hooks or hitch Maximum Rac...

Page 44: ...42...

Page 45: ...TCH LIGHT SWITCH Use the ignition switch to start the engine The key can be removed from the switch when it is in the OFF position OFF Turn the key to the OFF position to stop the engine Electrical ci...

Page 46: ...TCH WARNING Pressing the override button while the throttle is open can cause loss of control which may result in serious injury or death Always release the throttle before pressing the override butto...

Page 47: ...eration of the throttle system can result in an accident if the throttle lever sticks during operation Always check the lever for free movement and return before starting the engine Also check occasio...

Page 48: ...mode is set to AWD For more information see page 47 DRIVELINE SWITCH CALIFORNIA HD UTILITY LE AND ULTIMATE TRAIL MODELS On California and Utility models the AWD system is controlled by the AWD Moment...

Page 49: ...switch to AWD while the rear wheels have traction or are at rest The All Wheel Drive AWD system is controlled by the Driveline switch Engage AWD before getting into conditions where front wheel drive...

Page 50: ...disengage There is no limit to the length of time the vehicle may remain in AWD The vehicle automatically engages AWD when operating in reverse if the switch is set to either AWD position 2X4 MODE Whe...

Page 51: ...rcase damage Always switch to AWD or ADC 4X4 while the rear wheels have traction or are at rest ALL WHEEL DRIVE SYSTEM IF EQUIPPED On certain models the All Wheel Drive system AWD is controlled by a A...

Page 52: ...ar wheels regain traction When in AWD 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 automatical...

Page 53: ...r The 4X4 switch must be in the ADC 4X4 position Vehicle speed must be 15 MPH 25 km h or less The throttle must be closed throttle lever released The transmission must be in gear high low or reverse D...

Page 54: ...bar to apply the front and rear brakes These brakes are hydraulically activated disc type brakes that are activated by only one lever Always test brake lever travel and master cylinder fluid level bef...

Page 55: ...n accident After opening a bottle of brake fluid always discard any unused portion Check the brake fluid in the master cylinder before each ride 1 Position the ATV on a level surface 2 Position the ha...

Page 56: ...forward to engage the lock 4 Release the brake lever 5 To release the parking brake lock squeeze and release the brake lever It will return to its unlocked position The parking brake may relax if left...

Page 57: ...ntended to be used as a backup for the main brake system Should the main system fail use the auxiliary foot brake q The auxiliary foot brake is located on the inside of the right footrest Operate this...

Page 58: ...e lever to the desired gear NOTE Shifting gears with the engine speed above idle or while the vehicle is moving could cause transmission damage Whenever the ATV is left unattended always place the tra...

Page 59: ...Remove the five screws securing the plastic seat cover Lift the cover upward to remove it from the backrest frame 2 To adjust the backrest upward or downward loosen the four vertical adjustment bolts...

Page 60: ...on is for seat storage only Do not leave the backrest in the lowest position Always adjust the backrest to one of the three operating positions 6 Lower the operator backrest to create the passenger se...

Page 61: ...your model If the performance of the factory installed battery is inadequate due to operation in extreme cold or due to extended use of multiple electrical accessories your POLARIS dealer can assist Y...

Page 62: ...pper right corner of the gauge at start up If your model is equipped with a no button gauge use the MODE button on the left hand control to navigate the display menu NOTICE The use of a high pressure...

Page 63: ...area displays engine RPM ground speed or coolant temperature r Fuel Gauge The segments of the fuel gauge show the level of fuel in the fuel tank When the last segment clears a low fuel warning is act...

Page 64: ...ration is possible with key on engine off for up to 5 minutes Engine Hot This lamp illuminates to indicate an overheated engine If the indicator flashes a severe overheating condition exists Neutral T...

Page 65: ...g or max speed is enabled Lamp remains off when Geofencing and max speed settings are disabled DISPLAY AREA 1 Pressing the MODE button will change the information displayed in Area 1 q DISPLAY AREA 1...

Page 66: ...e will be displayed Trip 1 The vehicle Trip 1 mileage will be displayed Trip 2 The vehicle Trip 2 mileage will be displayed RPM The vehicle RPM will be displayed Voltage The vehicle s current battery...

Page 67: ...nt 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 backlight br...

Page 68: ...s before showing first menu item 2 Select Diagnostic Codes from the Options Menu by pressing the MODE button Toggle the Up Down Buttons to cycle through Code s NOTICE This option will only be availabl...

Page 69: ...ions Menu NOTICE OPTIONS will display on the screen for 3 seconds before showing first menu item 2 Select Units Distance from the Options Menu by pressing the MODE button Reference the image shown abo...

Page 70: ...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 71: ...units Cycles Hours t With the correct unit displayed Press the mode button which will set the unit y Toggle the Up Down Buttons to change the units Cycles 10s of Minutes u With the correct unit displa...

Page 72: ...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 73: ...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 74: ...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 75: ...ocedure to pair your phone with the vehicle s digital gauge NOTICE Bluetooth functionality is compatible with both iOS and Android phones For iOS phones you must go to the Settings option and enable n...

Page 76: ...74...

Page 77: ...ever operate the vehicle on pavement or on any public street road or highway including dirt and gravel roads 7 Use caution and drive at reduced speeds in conditions of reduced visibility such as fog r...

Page 78: ...trails open for recreational vehicle use As an off road enthusiast you represent the sport and can set a good example or a poor example for others to follow Tread lightly Operate with respect for the...

Page 79: ...filter at 25 hours or 250 miles 9 Check fluid levels of transmission and all gearcases after the first 25 hours of operation and every 100 hours thereafter BRAKE SYSTEM BREAK IN Apply only moderate b...

Page 80: ...essure page 123 Wheels fasteners Inspect ensure fastener tightness Frame nuts bolts fasteners Inspect ensure tightness Fuel and oil Ensure proper levels page 167 Coolant level Ensure proper level page...

Page 81: ...he left 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...

Page 82: ...feet on the footrests 5 Lean your upper body to the inside of the turn while supporting your weight on the outer footrest This technique alters the balance of traction between the rear wheels allowin...

Page 83: ...ese precautions 1 Do not operate on excessively rough slippery or loose terrain 2 Slow down when entering slippery areas 3 Engage 4X4 before wheels begin to lose traction NOTICE Severe damage to drive...

Page 84: ...refully before ascending any hill 5 Never climb hills with excessively slippery or loose surfaces 6 Keep both feet on the footrests 7 Shift body weight uphill 8 Proceed at a steady rate of speed and t...

Page 85: ...ith the transmission in forward gear Do not descend a hill with the transmission in neutral 5 Slow down Never travel down a hill at high speed 6 Drive straight downhill Avoid traveling down a hill at...

Page 86: ...tely necessary If crossing a sidehill is unavoidable follow these precautions 1 Slow down 2 Avoid crossing the side of a steep hill 3 Lean into the hill transferring your upper body weight toward the...

Page 87: ...side of the vehicle or on the left if the vehicle 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 lo...

Page 88: ...section of this manual and take the vehicle in for service at the first opportunity Your ATV can operate through water with a maximum recommended depth equal to the bottom of the footrests Follow the...

Page 89: ...ert for hazards such as logs rocks and low hanging branches 3 Travel slowly and use extra caution when operating on unfamiliar terrain Not all obstacles are immediately visible 4 Never attempt to oper...

Page 90: ...the throttle suddenly 7 Do not use the override switch unless additional wheel speed is required for vehicle movement Use the override with caution as rearward vehicle speed is greatly increased Do no...

Page 91: ...does not start return the key to the OFF position and wait five seconds before attempting to start again Activate the starter for another five seconds if necessary Repeat this procedure until the engi...

Page 92: ...ission in PARK 3 Turn the engine off 4 Engage the parking brake if equipped 5 Slowly release the brake pedal and make sure the transmission is in PARK before exiting the vehicle 6 Remove the ignition...

Page 93: ...s raises the center of gravity of the vehicle and creates a less stable operating condition SECURE ALL LOADS BEFORE OPERATING Unsecured loads can create unstable operating conditions which could resul...

Page 94: ...assenger 5 When operating over rough or hilly terrain reduce speed and cargo weight to maintain stable driving conditions 6 Do not obstruct the headlight beam with cargo 7 Use low forward gear when ha...

Page 95: ...aximum Vertical Hitch Weight NA 120 lbs 55 kg 570 Touring SP Maximum Towed Load Level Ground NA 1500 lbs 680 kg Maximum Vertical Hitch Weight NA 150 lbs 68 kg CARGO BOX DUMPING IF EQUIPPED NOTE Sports...

Page 96: ...ith 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 driver The rear tires will also catch the rear of the...

Page 97: ...event loss during transporting 5 Always tie the frame of the vehicle to the transporting unit securely with suitable straps or rope Do not attach tie straps to the front A arm bolt pockets racks or ha...

Page 98: ...96...

Page 99: ...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 105 7 Always keep the area around t...

Page 100: ...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 101: ...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 102: ...be released if the winch cable breaks This can result in SEVERE INJURY or DEATH See the Shock Loading section on page 105 Never hook the winch cable back onto itself This will damage the winch cable a...

Page 103: ...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 w...

Page 104: ...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 105: ...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 106: ...his 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 a...

Page 107: ...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 108: ...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 109: ...s 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 CONT...

Page 110: ...108...

Page 111: ...e adjust and replace parts as necessary When inspection reveals the need for replacement parts genuine POLARIS parts are available from your POLARIS dealer Equivalent parts may be used for emissions r...

Page 112: ...is reached first Record maintenance and service in the Maintenance Log ITEM MAINTENANCE INTERVAL WHICHEVER COMES FIRST REMARKS HOURS CALENDAR MILES KM Steering Pre Ride Inspect and make adjustments as...

Page 113: ...tion 50 H 3 M 500 800 Lubricate all fittings pivots cables etc Shift Linkage 50 H 3 M 500 800 Inspect D Steering 50 H 6 M 500 800 Lubricate XU Front Rear Suspension 50 H 6 M 500 800 Lubricate XU Throt...

Page 114: ...rs subjected to water mud etc D Clutches Drive Driven 100 H 12 M 1000 1600 Inspect clean replace worn parts D Wheel Bearings 100 H 12 M 1000 1600 Inspect replace as needed D Brake Fluid 200 H 24 M 200...

Page 115: ...emand Drive 9 oz 265 ml Maintain level at bottom of fill hole threads Front Prop Shaft U Joint Grease Grease fittings 3 pumps maximum every 500 miles before long periods of storage or after pressure w...

Page 116: ...using a non recommended oil may cause serious engine damage Always use the recommended oil Never substitute or mix oil brands OIL LEVEL NOTE Check the oil level when the engine is cold Never check th...

Page 117: ...gine Allow it to warm up at idle for two to three minutes 3 Stop the engine 4 Clean the area around the drain plug q 5 Place a drain pan under the crankcase 6 Remove the drain plug q Allow the oil to...

Page 118: ...ubricate the o ring on the new filter with a film of fresh engine oil Check to make sure the o ring is in good condition 4 Install the new filter and rotate it clockwise by hand until the filter gaske...

Page 119: ...K 1 Remove the fill plug q Check the oil level 2 Add the recommended fluid as needed to bring the level to the bottom of the fill hole threads 3 Reinstall the fill plug Torque to specification 4 Reins...

Page 120: ...demand drive fluid If the noise continues please see your POLARIS dealer or other qualified service facility for service Use the recommended fluid Use of other fluids may result in improper operation...

Page 121: ...er qualified service facility before operating the vehicle COOLING SYSTEM The engine coolant level is controlled or maintained by the recovery system The recovery system components are the recovery bo...

Page 122: ...ing system has been drained for maintenance or repair replace the coolant with fresh Antifreeze 50 50 Premix If the recovery bottle has run dry check the level in the radiator Add coolant as needed CA...

Page 123: ...are recommended to keep the brake system in good operating condition Check more often if brakes are used heavily under normal operation 1 Always keep brake fluid at an adequate level See the Master C...

Page 124: ...gage the under seat fasteners 5 Remove the seat SIDE PANEL REMOVAL To remove the side panel do the following 1 Remove the seat 2 Use a flat screwdriver to remove the plastic rivets securing the side p...

Page 125: ...or improperly installed tires will affect vehicle handling and could cause an accident resulting in serious injury or death Always follow all tire maintenance procedures as outlined in this manual an...

Page 126: ...the wheel WHEEL INSTALLATION 1 Place the transmission in PARK 2 Lock the parking brake 3 Place the wheel on the hub with the valve stem toward the outside and rotation arrows on the tire pointing tow...

Page 127: ...e wheel nut torques occasionally and when they ve been loosened for maintenance service Lug Nut Aluminum Wheels Front and Rear 30 ft lbs 41 N m PLUS 70 degrees 2 Piece Flange Nut Steel Wheels Front an...

Page 128: ...in a straight ahead position 3 Tie a length of string between two stands Position the stands so that the string is flush with the side of the rear tire If available you may use a long straight edge i...

Page 129: ...6 Reinstall the air box cover and the seat FUSE REPLACEMENT If the engine stops or will not start or if you experience other electrical failures a fuse may need replacement Locate and correct any sho...

Page 130: ...leaves a residue causing a hot spot that will shorten the life of the lamp If fingers do touch a lamp clean it with denatured alcohol CAUTION Hot components can cause burns to skin Allow lamps to cool...

Page 131: ...asure the distance from the floor to the center of the headlight and make a mark on the wall at the same height 3 Start the engine Turn the headlight switch to high beam 4 Observe the headlight aim on...

Page 132: ...e o rings from the headlight mounting tabs 5 Pull the headlight housing up from bracket for removal 6 Reverse the steps to install the new housing and reassemble the pod LOWER HEADLAMP REPLACEMENT 1 T...

Page 133: ...st the light for proper operation X2 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 co...

Page 134: ...heck the spark plug for correct color CAUTION A hot exhaust system and engine can cause burns Wear protective gloves when removing a spark plug for inspection Allow engine to cool before removing spar...

Page 135: ...ck the air box If water is present dry the air box and replace the filter with a new filter If equipped remove the air box drain plug to drain water Reinstall the drain plug CAUTION Serious damage cou...

Page 136: ...Do not go under the machine while it is inclined Place the transmission in PARK lock the parking brake and block the wheels to prevent roll back Failure to heed these warnings could result in serious...

Page 137: ...be in the muffler drive the machine onto the incline so the front of the machine is ONE FOOT HIGHER than the rear Set the hand brake and block the wheels Place the transmission in PARK lock the parkin...

Page 138: ...strength so that a failure may occur at a high speed The PVTsystem has been precision balanced Any modification will cause the system to be out of balance creating vibration and additional loads on co...

Page 139: ...uld be around 3000 RPM This is well above the engagement speed of 1600 1800 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...

Page 140: ...an 5 seconds 5 Allow the engine RPM to settle to idle speed then shift the transmission to low range 6 Test for belt slippage If the belt slips repeat the process Your vehicle requires service as soon...

Page 141: ...that it can be installed in the same direction 10 Insert the provided clutch tool between the slides and rotate the tool to spread the sheaves Spanner Wrench Spreader PN 2877408 NOTICE Ensure the too...

Page 142: ...orient the new belt so you may read the text 1 Spread the sheaves and walk the drive belt on to the drive clutch and driven clutch Spanner Wrench Spreader PN 2877408 NOTICE Ensure the tool is square...

Page 143: ...bolts retaining the lower LH frame support to the frame Torque bolts to specification TORQUE Lower LH Frame Support Fasteners 37 ft lbs 50 N m 6 Install the left rear wheel and torque wheel nuts to sp...

Page 144: ...142 MAINTENANCE...

Page 145: ...f corrosion If cleaning is necessary remove corrosion with a stiff wire brush Wash with a solution of one tablespoon baking soda and one cup water Rinse well with tap water and dry off with clean shop...

Page 146: ...y install the black negative cable last NOTICE Batteries on SP models are mounted outside the frame in a similar location All removal and installation steps are the same 1 Clean battery cables and ter...

Page 147: ...entional Batteries Only WARNING Vent tube must be free from obstructions and kinks and securely installed If not battery gases could accumulate and cause an explosion The vent tube should be routed aw...

Page 148: ...charged at the factory Never pry the 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 b...

Page 149: ...NDARD AMPS SPECIFIED ON TOP OF BATTERY 100 12 6 12 8 volts Conventional Low Maintenance Battery check after 60 days AGM Battery check after 30 days None required 50 75 12 0 12 5 volts Needs charge 5 1...

Page 150: ...tery life All Polaris ORV models include either a Conventional battery or a Low Maintenance battery CONVENTIONAL BATTERY The battery is NOTactivated when packaged Distilled water and electrolyte added...

Page 151: ...tery Never put the sealing cap back onto the battery The gas pressure can cause the battery to rupture Let the battery sit for 30 minutes after you add the initial electrolyte Once absorbed fill the b...

Page 152: ...with the battery to activate the battery Keep the electrolyte container in place for 20 minutes or longer until the container is completely empty If necessary gently tap the container to empty it Once...

Page 153: ...ed by 10 30 of the battery s full potential Nominal voltage is 12 6 to 12 8 Volts when fully charged If the voltage falls below 12 5V charge it immediately or the battery service life and vehicle perf...

Page 154: ...will damage the case and shorten the life of the battery If you do not drive the vehicle for more than TWO weeks maintain the battery with the BatteryMINDer 2012 AGM 12V 2 0 Amp charger If you plan to...

Page 155: ...limited steering or loosening of the handlebars resulting in loss of control and serious injury or death Follow the adjustment procedures exactly or see your POLARIS dealer for service 1 Remove the up...

Page 156: ...nents Labels and decals If an informational or graphic label becomes illegible or comes off contact your POLARIS dealer to purchase a replacement Replacement safety labels are provided by POLARIS at n...

Page 157: ...2 Add POLARIS Carbon Clean Fuel Treatment or POLARIS Fuel Stabilizer or equivalent fuel treatments or stabilizers Follow the instructions on the container for the recommended amount Carbon Clean remo...

Page 158: ...from the spark plug cavities into the hole at the front of the cylinder head and appear to be an oil leak 3 Reinstall the spark plugs Torque to specification 4 Apply dielectric grease to the inside of...

Page 159: ...in PARK 3 Lock the parking brake 4 Secure the fuel cap oil cap and seats 5 Always tie the frame of the ATV to the transporting unit securely with suitable straps or rope Do not attach tie straps to t...

Page 160: ...158...

Page 161: ...Storage Box Capacity 90 lbs 40 8 kg Rear Rack Capacity 180 lbs 81 6 kg Receiver Hitch Tongue Capacity 120 lbs 55 kg 570 570 EPS 150 lbs 68 Kg 570 SP Rear rack capacity and tongue weight not to exceed...

Page 162: ...PVT POLARIS Variable Transmission Front Suspension MACPHERSON RIDE strut with 8 2 21 cm travel 570 570 EPS Double A Arm with 8 2 21 cm travel 570 SP Rear Suspension Linear rate with 9 5 24 cm travel T...

Page 163: ...0 0 6000 25 52G PN 5632409 EBS Black PN 7043595 NON EBS Black PN 7043594 EBS RED PN 3234452 NON EBS PN 7041782 EBS PN 3224356 NON EBS PN 5132344 1800 3700 6000 12000 25 48 PN 5633217 Black PN 7043594...

Page 164: ...Overall Width 48 in 122 cm Overall Height 48 in 122 cm Wheelbase 56 in 142 2 cm Ground Clearance 11 in 28 cm Minimum Turning Radius 65 in 165 cm unloaded Engine Dual overhead cam 4 valve 4 stroke sin...

Page 165: ...Brake Parking Hydraulic lock all wheel Headlight 1 Single Beam on Headlight Pod 50 watt 2 Single Beam on Bumper 50 watt Taillights 8 26 watts Brake Light 26 9 watts Instrument Cluster LCD CLUTCHING AL...

Page 166: ...ck Capacity 180 lbs 81 kg Cargo Box Capacity 800 lbs 362 kg Hitch Tongue Weight 150 lbs 68 kg Rear box capacity and tongue weight not to exceed 400 lbs 181 kg Hitch Towing Rating 1500 lbs 680 kg Unbra...

Page 167: ...ate with 9 5 24 cm travel Transmission H L N R P Gear Reduction Low 23 91 1 Gear Reduction Reverse 21 74 1 Gear Reduction Forward 9 75 1 Drive Ratio Front 3 82 1 Tires Pressure Front 26x8 12 7 psi 48...

Page 168: ...SPRING HELIX Meters Feet 0 1800 0 6000 25 52G PN 5632409 Black PN 7043594 Red PN 3234452 EBS PN 3224356 1800 3700 6000 12000 25 48 PN 5633217 Black PN 7043594 Non EBS Red PN 3234451 Non EBS PN 5132344...

Page 169: ...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 170: ...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 168 POLARIS PRODUCTS...

Page 171: ...ed in the chart to the electronic control unit is shorted 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...

Page 172: ...cuit Open Grounded 652 5 Driver Circuit Short to B 652 3 Driver Circuit Grounded 652 4 Ignition Coil Primary Driver 1 MAG Driver Circuit Short to B 1268 3 Ignition Coil Primary Driver 2 PTO Driver Cir...

Page 173: ...B 1321 3 Driver Circuit Grounded 1321 4 Chassis Relay Driver Circuit Open Grounded 520208 5 Driver Circuit Short to B 520208 3 Driver Circuit Grounded 520208 4 All Wheel Drive Control Driver Circuit O...

Page 174: ...DELS ONLY Vehicle Speed Sensor Received Network Data In Error 84 19 System Power Voltage Above Normal Or Shorted To High Source 168 3 Voltage Below Normal Or Shorted To Low Source 168 4 Engine Speed R...

Page 175: ...Above Normal Operating Range Moderately Severe Level 520225 16 EPAS Communications Receive Data Error Data Erratic Intermittent Or Incorrect 520226 2 Position Encoder Error Root Cause Not Known 52022...

Page 176: ...sive 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 throttle ap...

Page 177: ...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 178: ...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 179: ...plug gap or heat range Set gap to specs or replace plug Loose ignition connections Check all connections and tighten Low battery voltage Recharge the battery Incorrect fuel Replace with fresh recomme...

Page 180: ...178...

Page 181: ...r other qualified person but any such transfer will not extend the original term of the warranty The duration of this warranty may vary by international region based upon local laws and regulations RE...

Page 182: ...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 183: ...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 184: ...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 185: ...ot followed the procedure set above your product will no longer be eligible for warranty or service bulletin coverage of any kind other than safety bulletins Products registered to government official...

Page 186: ...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 187: ...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 188: ...dels are designed and built with features such as a reduced cargo box capacity Any modifications to these features may be a violation of the applicable California regulations and may void this limited...

Page 189: ...aintenance listed in your owner s manual Polaris recommends that you retain all receipts covering maintenance on your OHRV EVAP but Polaris cannot deny warranty solely for the lack of receipts or for...

Page 190: ...188...

Page 191: ...MAINTENANCE LOG MAINTENANCE LOG Use the following chart to record periodic maintenance DATE MILES KM OR HOURS TECHNICIAN SERVICE PERFORMED COMMENTS 189 MAINTENANCE LOG...

Page 192: ...190...

Page 193: ...and Caster 153 Cargo Box Dumping X2 and UTE 93 Cargo Warning 91 Clean the Exterior 155 Clothing 12 Cold Weather Operation 89 Cooling System 119 Crankcase Emission Control System 107 Crossing Hillside...

Page 194: ...30 Headlight Lamp Replacement 128 Headlight Switch 45 Helmet 12 High Beam Adjustment 129 Hot Exhaust Systems 23 How To Obtain Warranty Service 182 I Ignition Switch Light Switch 43 Improper Cargo Load...

Page 195: ...Part Numbers 167 Passenger Safety Warning 27 31 36 Passenger Seat X2 57 Passenger Seat Backrest Touring 57 Periodic Maintenance 109 Physical Control of the Vehicle 16 Physical Skills 22 Polaris Produ...

Page 196: ...ches Driveline Switch 46 Driveline Switch California HD Utility LE Ultimate Trail Models 46 Engine Stop Switch 44 Mode Reverse Override Switch 44 Overview 43 Throttle Lever 45 T Taillights Brake Light...

Page 197: ......

Page 198: ...chniques 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...

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