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Polaris Sportsman Touring 570 EPS 2021, Owner'S Manual

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Polaris Sportsman Touring 570 EPS 2021 Owner'S Manual Download Page 173

WARRANTY

LIMITED WARRANTY

POLARIS Industries Inc., 2100 Highway 55, Medina, MN 55340 (POLARIS)
gives a TWO YEAR LIMITED WARRANTY on all components of your POLARIS
vehicle against defects in material or workmanship. POLARIS further warrants
that the spark arrester in this product will meet the efficiency requirements of
USFS standard 5100-1C for at least 1000 hours when subjected to normal use
and when maintenance and installation are in accordance with POLARIS
recommendations.

This warranty covers parts and labor charges for repair or replacement of
defective parts and begins on the date of purchase by the original retail
purchaser. This warranty is transferable to another owner during the warranty
period through a POLARIS dealer, 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.

REGISTRATION

At the time of sale, the Warranty Registration Form must be completed by your
dealer and submitted to POLARIS within ten days of purchase. 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 your proof of warranty coverage. If you have
not signed the original registration and received the customer copy, please
contact your dealer immediately. NO WARRANTY COVERAGE WILL BE
ALLOWED UNLESS YOUR VEHICLE IS REGISTERED WITH POLARIS. Initial
dealer preparation and set-up of your vehicle is very important in ensuring
trouble-free operation. Purchasing a machine in the crate or without proper
dealer set-up will void your warranty coverage.

171

WARRANTY

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Summary of Contents for Sportsman Touring 570 EPS 2021

Page 1: ...g 570 SP Tractor Sportsman X2 570 EPS Tractor For Maintenance and Safety WARNING Read this manual carefully It contains important safety information This is an adult vehicle only Operation is prohibited for those under 16 years of age Downloaded from ManualsNet com search engine ...

Page 2: ... service your vehicle in a well ventilated area and wear gloves or wash your hands frequently when servicing your vehicle For more information go to www P65Warnings ca gov passenger vehicle WARNING Read understand and follow all of the instructions and safety precautions in this manual and on all product labels Failure to follow the safety precautions could result in serious injury or death For vi...

Page 3: ...2021 Tractor Owner s Manual Sportsman Touring 570 EPS Sportsman Touring 570 SP Sportsman X2 570 EPS Downloaded from ManualsNet com search engine ...

Page 4: ...ned within this publication is based on the latest product information at the time of publication Due to constant improvements in the design and quality of production components some minor discrepancies may result between the actual vehicle and the information presented in this publication Depictions and or procedures in this publication are intended for reference use only No liability can be acce...

Page 5: ...r POLARIS vehicle making it the finest machine we ve ever produced For safe and enjoyable operation of your vehicle be sure to follow the instructions and recommendations in this owner s manual Your manual contains instructions for minor maintenance but information about major repairs is outlined in the POLARIS Service Manual and can be performed by a factory certified Master Service Dealer MSD te...

Page 6: ...4 WELCOME Downloaded from ManualsNet com search engine ...

Page 7: ...res and Controls 35 Operation 75 Winch Guide 99 Emission Control Systems 109 Maintenance 111 Specifications 157 POLARIS Products 163 Troubleshooting 165 Warranty 171 Maintenance Log 177 5 Downloaded from ManualsNet com search engine ...

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Page 9: ... this manual with the vehicle Never operate this vehicle without proper instruction Take an authorized training course See the Safety Training section for more information This vehicle is an ADULT VEHICLE ONLY You MUST be at least age 16 and have a valid driver s license to operate this vehicle Always use the cab nets or doors while riding in this vehicle Always keep hands feet and all other body ...

Page 10: ...dous 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 injury NOTICE NOTICE provides key information by clarifying instructions IMPORTANT IMPORTANT provides key reminders during disassembly assembly and inspection of components The Prohibition Safety Sign indicates an action ...

Page 11: ...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 The vehicle serial number q can be found stamped on lower frame rail on the rear left hand side of the vehicle on all models Vehicle Model Number Frame VIN q Engine Serial Number w Key Number e 9 INTRODUCTIO...

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Page 13: ...d ATV RiderCoursesm that is available to you and your eligible family members 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 basis If you purchased a used POLARIS ATV in the United States you can enroll in the ATV RiderCoursesm for a fee Call ATV Enrollm...

Page 14: ...s sprayers and large racks may change vehicle handling Use only POLARIS approved accessories Know their function and effect on the vehicle SAFE RIDING GEAR Always wear helmet eye protection gloves long sleeve shirt long pants over the ankle boots and seat belt if equipped at all times Protective gear reduces the chance of injury q Helmet w Eye Protection e Long Sleeves r Gloves t Long Pants y Over...

Page 15: ...etter 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 label EYE PROTECTION Do not depend on eyeglasses or sunglasses for eye protection Whenever riding this POLARIS vehicle always wear shatterproof goggles or use a shatterproof helmet face shield POLARIS recommends wearing approved Personal Protec...

Page 16: ...er s Manual and all warning and instruction labels before operating the vehicle AGE RESTRICTIONS This vehicle is an ADULT VEHICLE ONLY Operation is prohibited for anyone under 16 years of age Never allow anyone under 12 years of age to ride as a passenger on a 2 up vehicle Even though a child may be within the recommended age group for operating some ATVs he she may not have the skills abilities o...

Page 17: ...assenger on a 2 up ATV PROTECTIVE APPAREL Riding in this vehicle without wearing an approved helmet and protective eyewear increases the risk of a serious injuries in the event of an accident Operator and all passenger must always wear an approved helmet that fits properly and eye protection goggles or face shield OPERATING ON PUBLIC ROADS This vehicle is approved for on road use 15 SAFETY Downloa...

Page 18: ...s described in the owner s manual PHYSICAL CONTROL OF THE ATV Removing a hand from the handlebars or feet from the footrests during operation can reduce your ability to control the vehicle or cause loss of balance and ejection from the ATV If the operator s feet are not firmly planted on the footrests they could come into contact with the rear wheels or other moving parts and lead to accident or i...

Page 19: ...ions TURNING IMPROPERLY Turning improperly could cause loss of traction loss of control accident or rollover Always follow proper procedures for turning as described in the owner s manual Never turn abruptly or at sharp angles Never turn at high speeds Practice turning at slow speeds before attempting to turn at faster speeds JUMPS AND STUNTS Attempting wheelies jumps and other stunts increases th...

Page 20: ...than 15 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 the owner s manual NOTE A special technique is required when braking while traveling downhill See the Driving Downhill section Always descend a hill with the transmission in forward gear Do not descend a hill with the tran...

Page 21: ...ual OPERATING OVER OBSTACLES Improperly operating over obstacles could cause loss of control or rollover Before operating in a new area check for obstacles Avoid operating over large obstacles such as rocks and fallen trees If unavoidable use extreme caution and always follow proper operating procedures as outlined in this manual OPERATING IMPROPERLY IN REVERSE Improperly operating in reverse coul...

Page 22: ...ss of traction loss of control accident or rollover Do not operate on excessively rough slippery or loose terrain Always use extra caution on rough slippery or loose terrain OPERATING THROUGH DEEP WATER Operating the ATV through deep or fast flowing water could cause the tires to float causing loss of control or overturn Avoid operating the ATV through deep or fast flowing water If it s unavoidabl...

Page 23: ...ould cause loss of control or an accident Never modify the ATV through improper installation or use of accessories All parts and accessories added to the vehicle must be genuine POLARIS Industries Inc or equivalent components designed for use on this ATV and should be installed and used according to approved instructions An authorized dealer can assist IMPROPER CARGO LOADING Overloading the ATV or...

Page 24: ...r improperly dismounting while climbing a hill could cause a rollover Always maintain a steady speed when climbing a hill Always engage ADC mode if equipped before ascending or descending a hill If ADC mode is not equipped apply AWD mode before ascending or descending a hill If all forward speed is lost Lean forward to keep body weight uphill A passenger should also lean uphill Apply the brakes Lo...

Page 25: ...g on a road or street Use caution and drive at reduced speeds in conditions of reduced visibility such as fog rain and darkness Clean headlights frequently and replace burned out headlamps promptly PHYSICAL SKILLS Safe operation of this rider active vehicle requires good judgement and physical skills Persons with cognitive or physical disabilities who operate this vehicle have an increased risk of...

Page 26: ...nspect the underside of the vehicle and areas near the exhaust system after driving through tall grass weeds brush other tall ground cover and muddy conditions Promptly remove any grass debris or foreign matter clinging to the vehicle and pay particular attention to the exhaust system area OCCUPANT PROTECTION DEVICE This vehicle is not equipped with an Occupant Protection Device capable of protect...

Page 27: ...y enclosed cab Rubber tires rubber handgrips and a foam seat will not protect a rider from lightning strikes Always seek safe shelter when lightning is imminent UNAUTHORIZED USE OF THE VEHICLE Leaving the keys in the ignition can lead to unauthorized use of the vehicle by someone under the age of 16 without a drivers license or without proper training This could result in an accident or rollover A...

Page 28: ... depicted in this manual differ from the labels on your vehicle always read and follow the instructions of the labels on the vehicle If any label becomes illegible or comes off contact your POLARIS dealer to purchase a replacement Replacement safety labels are provided by POLARIS at no charge The part number is printed on the label 26 SAFETY Downloaded from ManualsNet com search engine ...

Page 29: ... reference only Your model may differ slightly q General Alert w Override Alert e Tether Switch Alert r 4X4 AWD Alert t Hill Operation Alert y Greasing Points Alert u Rack Alert i Clutch Cover Alert o Tire Pressure Alert 27 SAFETY Downloaded from ManualsNet com search engine ...

Page 30: ...er use alcohol or drugs before or while operating NEVER carry more than one passenger This vehicle is approved for on road use OVERRIDE ALERT 7181544 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 Always apply throttle gradually while in reverse 28 SAFETY Downloaded from ManualsNet com search engine...

Page 31: ... engage 4X4 AWD if the rear wheels are spinning This may cause severe drive shaft and clutch damage TIRE PRESSURE ALERT 7183263 TIRE PRESSURE IN kPa FRONT 48 3 kPa REAR 48 3 kPa CLUTCH COVER ALERT 7181427 Keep body parts away from belt Label Location on the clutch cover 29 SAFETY Downloaded from ManualsNet com search engine ...

Page 32: ... ALERT 7300027 Lubricate as recommended RACK ALERT ALERT DO NOT TOW FROM RACK OR BUMPER Tow only from tow hooks or hitch Maximum Rack Loads FRONT 41 kg REAR 82 kg 30 SAFETY Downloaded from ManualsNet com search engine ...

Page 33: ...Your model may differ slightly q General Alert w Override Alert e Tether Switch Alert r 4X4 AWD Alert t Hill Operation Alert y Greasing Points Alert u Rack Alert i Clutch Cover Alert o Tire Pressure Alert a Crush Alerts s Box Alerts 31 SAFETY Downloaded from ManualsNet com search engine ...

Page 34: ...er use alcohol or drugs before or while operating NEVER carry more than one passenger This vehicle is approved for on road use OVERRIDE ALERT 7181544 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 Always apply throttle gradually while in reverse 32 SAFETY Downloaded from ManualsNet com search engine...

Page 35: ... drive shaft and clutch damage HILL OPERATION ALERT 7181536 Never operate this vehicle on HILLS steeper than 15 GREASING POINTS ALERT 7300027 Lubricate as recommended CLUTCH COVER ALERT 7181427 Keep body parts away from belt Label Location on the clutch cover 33 SAFETY Downloaded from ManualsNet com search engine ...

Page 36: ...ack Loads FRONT 41 kg BOX ALERT 7182312 Remove flammable material containers from box before filling Passengers can be thrown off This can cause serious injury or death Never carry passengers in cargo box Maximum Box Load 181 kg CRUSH ALERTS To prevent a crushing injury to hands and fingers keep hands and fingers away from the lower front edge of the cargo box while lowering the box 34 SAFETY Down...

Page 37: ...y q Ignition Switch w Engine Stop Switch e Mode Reverse Override Switch r Headlight Switch t Working Light Switch if equipped y Driveline Mode Switch u Throttle Switch i Auxiliary Outlet o Variable Speed Limiter Switch if equipped 35 FEATURES AND CONTROLS Downloaded from ManualsNet com search engine ...

Page 38: ...LEFT HANDLEBAR SWITCHES q Light Switch w Engine Stop Switch e Hazard Switch r Turn Signal Switch t Horn Switch y Override Switch 36 FEATURES AND CONTROLS Downloaded from ManualsNet com search engine ...

Page 39: ... result in serious injury or death End all electrical power to the vehicle The LIGHTS ON position turns the headlights on The engine stop switch must be in the RUN position Start the engine The headlights are not on in this position After starting the engine release the key switch to the PARKING LIGHTS ON position The parking lights and taillights are on in this position 37 FEATURES AND CONTROLS D...

Page 40: ...is vehicle is equipped with a reverse speed limiter system To gain additional wheel speed while backing release the throttle and depress the override switch WARNING Pressing the override switch 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 switch The reverse override switch also acts as a MO...

Page 41: ...leased WORK LIGHT SWITCH IF EQUIPPED The work light switch controls a light located in the pod Use the light when additional light is needed at the front of the vehicle but turn the work light off when driving the vehicle on road TURN SIGNAL SWITCH Push the toggle switch either left or right to activate the corresponding turn signal light The indicator in the gauge will also flash Return the toggl...

Page 42: ...thers of an emergency or other situation requiring caution HORN SWITCH Press the horn switch to sound the horn VARIABLE LOW SPEED SWITCH IF EQUIPPED The variable low speed switch if equipped allows you to limit the speed of your ATV The speed limiter can be set at any speed between 11 22 km h To activate the variable low speed feature the following conditions must all be met The Engine must be run...

Page 43: ...e control could result in failure to perform as designed which could result in an accident Do not attempt to modify the throttle control system or replace it with any after market throttle mechanisms Engine speed and vehicle movement are controlled by pressing the throttle lever q The throttle lever is spring loaded Engine speed returns to idle when the lever is released This ATV is equipped with ...

Page 44: ...ake lever is depressed If brake fluid pressure is lost or a drop in pressure is detected the brake warning light will illuminate NOTICE The brake monitoring system is very sensitive Resting your fingers on the brake lever may cause the brake warning indicator to illuminate It is not recommended to rest hand on the brake lever while the vehicle is in motion If the brake warning indicator lamp false...

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Page 46: ...uid level is full When fluid is low the eye will be clear 4 If the fluid level is low remove the cover screws and add fluid to the fill line Do not overfill Use DOT 4 brake fluid only 5 Reinstall the cover Torque screws to 7 in lbs 8 Nm 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 causes the boil...

Page 47: ... 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 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 position Neve...

Page 48: ...rear wheels slide while using the auxiliary brake reduce brake pedal pressure to brake the rear wheels without skidding NOTE If service brake system is fully functioning the auxiliary foot brake will brake on 4 wheels The auxiliary brake can be used when starting the vehicle To start the vehicle using the auxiliary foot brake depress the foot brake and turn the ignition key to the start position B...

Page 49: ... POWER STEERING IF EQUIPPED Electronic power steering EPS if equipped engages when the ignition key is turned to the ON position EPS remains engaged whether the vehicle is moving or idle See the Instrument Cluster section for EPS Warning Indicator information 47 FEATURES AND CONTROLS Downloaded from ManualsNet com search engine ...

Page 50: ...l with ethanol content greater than 10 percent such as E 85 fuel Compatible fuel types E5 E10 PASSENGER SEAT BACKREST TOURING The passenger backrest can be adjusted vertically 1 Unzip the two zippers at the bottom of the backrest pad Lift the pad upward to remove it from the backrest frame 2 To adjust the backrest upward or downward loosen the four vertical adjustment screws q on the front side of...

Page 51: ...led battery is inadequate due to operation in extreme cold or due to extended use of multiple electrical accessories your POLARIS dealer can assist Your dealer can provide any installation procedures that may differ for an extreme use battery BATTERY CHARGE PORT Your vehicle is equipped with a battery charge port q The battery charge port allows you to quickly and easily connect a battery charger ...

Page 52: ...ction for procedures The values below are specific to the factory installed rear hitch For the maximum vertical load and maximum towable mass on the hitch at the vehicle level see the Specifications chapter REAR HITCH SPECIFICATIONS PER COMPONENT CERTIFICATE Maximum Vertical Load 85 kg applied on coupling point Maximum Towable Mass 2000 kg Approval E20 55R 01 4430 Maximum Dynamic Force D 10 2 kN R...

Page 53: ...itch pin w 3 Install the hitch to the receiver 4 Reinstall the hitch pin from the left side of the hitch through the bore of both the receiver and the hitch 5 Reinstall the cotter pin Make sure the hitch assembly is secure at that the cotter pin is properly engaged over the hitch pin NOTICE After 1000 km of use tighten the bolt holding the trailer ball to the hitch to 445 N m 51 FEATURES AND CONTR...

Page 54: ... 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 transmission in PARK and lock the parking brake TIP To extend belt life use low forward gear when pulling a heavy load at less than seven miles per hour for extended periods and when operating uphill at a slow speed 52 FEATUR...

Page 55: ...uge will display AWD 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 the AWD position Once enabled AWD remains enabled until the switch is turned off If the switch is turned off while the demand drive unit is moving it will not disengage until the rear wheels regain traction When in AWD th...

Page 56: ...when it touches the ground again ADC MODE IF EQUIPPED The ADC system allows engine braking to all four wheels when the vehicle descends a hill or incline Always engage ADC mode if equipped before ascending or descending a hill ENGAGING FOUR WHEEL DESCENT CONTROL The 4WDC system will automatically engage when all of the following conditions occur 4WDC is engaged The throttle must be closed throttle...

Page 57: ...ble service hour interval ground speed or engine RPM e Display Area 1 This 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 activated All segments including the fuel icon will flash Refuel immediately t Service Indicator A flashing wrench symbol alerts ...

Page 58: ...ere overheating condition exists r Neutral This lamp illuminates when the transmission is in neutral and the ignition key is in the ON position t Helmet Seat Belt This lamp flashes for several seconds when the key is turned to the ON position The lamp is a reminder to wear helmet and seat belt if equipped before operating y High Beam This lamp illuminates when the headlamp switch is set to high be...

Page 59: ...AREA 1 Pressing the MODE button will change the information displayed in Area 1 q Speed Engine Temperature RPM Ambient Temperature Optional 57 FEATURES AND CONTROLS Downloaded from ManualsNet com search engine ...

Page 60: ...A 2 Toggle the Up Down buttons to change the information displayed in Area 2 w Odometer Engine Temperature Trip 1 Ambient Temperature Optional 58 FEATURES AND CONTROLS Downloaded from ManualsNet com search engine ...

Page 61: ...Trip 2 RPM Voltage Speed Engine Hours Service Hours 59 FEATURES AND CONTROLS Downloaded from ManualsNet com search engine ...

Page 62: ...present or stored Units Distance Select MPH or KPH Units Temp Select between F and C Clock Select between 12H or 24H and set time Backlight Color Select between Blue or Red Backlight Level Set backlight brightness level Service Hours View Set Service hours Exit Menu Exit 60 FEATURES AND CONTROLS Downloaded from ManualsNet com search engine ...

Page 63: ...q Press the MODE button w Toggle the Up Down Buttons to change the units MPH or KPH e With the correct unit displayed Press the mode button which will set the unit and return to the Options Menu 3 To exit the Options Menu the user can select Exit Menu function from Options Menu can hold Mode Button and exit out of Options Menu or not press any button for 10 seconds which will exit out of the Optio...

Page 64: ...e 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 Options Menu 3 To exit the Options Menu the user can select Exit Menu function from Options Menu can hold Mode Button and exit out of Options Menu or not press any button for 10 seconds which will exit out of the Options...

Page 65: ...e 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 displayed Press the mode button which will set the unit i Toggle the Up Down Buttons to change the units Cycles 1s of Minutes o With the correct unit displayed Press the mode button which will set the unit and return to the Options me...

Page 66: ...ress 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 Options Menu 3 To exit the Options Menu the user can select Exit Menu function from Options Menu can hold Mode Button and exit out of Options Menu or not press any button for 10 seconds which will exit out of the Options...

Page 67: ... 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 return to the Options Menu 3 To exit the Options Menu the user can select Exit Menu function from Options Menu can hold Mode Button and exit out of Options Menu or not press any button for 10 seconds which will exit out of the...

Page 68: ... have counted down to 0 0 reselect the existing setpoint or select a new service hour value 3 To exit the Options Menu the user can select Exit Menu function from Options Menu can hold Mode Button and exit out of Options Menu or not press any button for 10 seconds which will exit out of the Options Menu BLUETOOTH OPERATION IF EQUIPPED The Bluetooth functionality allows users to pair their phones w...

Page 69: ... range No further action is required by the user at this point NOTE Once the digital gauge is powered off Bluetooth connectivity will cease Also when a new phone is paired with the digital gauge all missed call and text information from the previous phone will be erased Up to 16 different phone pairings can be saved to the digital gauge The digital gauge does not support systems below Android vers...

Page 70: ...ll clear any save fault codes from the gauge Reference the image shown above q Area A will Display FMI XX w Area B will Display SPN XXXXXX e Clock Area will Display Count XXX 3 To exit the Options Menu the user can select Exit Menu function from Options Menu can hold Mode Button and exit out of Options Menu or not press any button for 10 seconds which will exit out of the Options Menu DIAGNOSTIC D...

Page 71: ...rature Too High 110 16 Engine Overheat Shutdown 110 0 Intake Air Temperature Sensor Voltage Too High 105 3 Voltage Too Low 105 4 Manifold Absolute Pressure Sensor Voltage Too High 102 3 Voltage Too Low 102 4 Signal Out of Range 102 2 Crankshaft Position Sensor Circuit Fault 636 8 Plausibility Fault 636 2 Vehicle Speed Signal Speed Too High 84 8 Plausibility Fault 84 2 Gear Sensor Signal Voltage To...

Page 72: ...ver Circuit Short to B 1347 3 Driver Circuit Grounded 1347 4 Fan Relay Driver Circuit Driver Circuit Open Grounded 1071 5 Driver Circuit Short to B 1071 3 Driver Circuit Grounded 1071 4 Idle Air Control Driver Circuit Open Grounded 634 5 Driver Circuit Short to B 634 3 Driver Circuit Grounded 634 4 Position Out of Range 634 7 Starter Enable Circuit Driver Circuit Open Grounded 1321 5 Driver Circui...

Page 73: ... Too Low 520194 4 Signal Out of Range 520194 2 Throttle Stuck 520194 7 Active Descent Control System Driver Circuit Open Grounded 520203 5 Driver Circuit Short to B 520203 3 Driver Circuit Grounded 520203 4 Idle Speed Speed Too High 520211 3 Speed Too Low 520211 4 Right Handlebar Switches Momentary Driveline Mode Switch Press 520468 31 DIAGNOSTIC CODES COMPONENT CONDITION SPN FMI EPS MODELS ONLY V...

Page 74: ...rmal Operational Range Most Severe Level 190 0 Data Erratic Intermittent Or Incorrect 190 2 Received Network Data In Error 190 19 ECU Memory Bad Intelligent Device Or Component 628 12 Out Of Calibration 628 13 Calibration Out Of Calibration 630 13 Steering Over Current Shut Down Current Above Normal Or Grounded Circuit 520221 6 Steering Excessive Current Error Current Above Normal Or Grounded Circ...

Page 75: ...t 520226 2 Condition Exists 520226 31 Position Encoder Error Root Cause Not Known 520228 11 Bad Intelligent Device Or Component 520228 12 Condition Exists 520228 31 EPAS Software Error Bad Intelligent Device Or Component 520229 12 Condition Exists 520229 31 EPAS Power Save Condition Condition Exists 520231 31 EPS SEPIC Voltage Error Voltage Above Normal Or Shorted To High Source 524086 3 Voltage B...

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Page 77: ...ction on your part is as important as a proper break in period Careful treatment of a new engine and drive components will result in more efficient performance and longer life for these components Perform the following procedures carefully NOTICE Excessive heat build up during the first three hours of operation will damage close fitted engine parts and drive components Do not operate at full throt...

Page 78: ...hange both the oil and the filter at 25 hours or one month 9 Check fluid levels of transmission and all gearcases after the first 25 hours of operation and every 100 hours thereafter PVT BREAK IN CLUTCHES BELT A proper break in of the clutches and drive belt will ensure a longer life and better performance Break in the clutches and belt by operating at slower speeds during the break in period as r...

Page 79: ...ear suspension Inspect lubricate if necessary page 116 Steering Ensure free operation Tires Inspect condition and pressure page 131 Wheels fasteners Inspect ensure fastener tightness page 131 page 132 Frame nuts bolts fasteners Inspect ensure tightness Fuel and oil Ensure proper levels page 32 page 117 Coolant level Ensure proper level page 124 Coolant hoses Inspect for leaks Throttle Ensure prope...

Page 80: ...f the vehicle grasp the left handlebar grip with your left hand Step onto the footrest and place your right foot and leg across the seat Sit astride the vehicle If boarding from the right side of the vehicle grasp the right handlebar grip with your right hand Step onto the footrest and place your left foot and leg across the seat Sit astride the vehicle DISMOUNTING 1 Position the vehicle on a leve...

Page 81: ...the ON position to engage the starter Activate the starter for a maximum of five seconds releasing the key when the engine starts 6 If the engine 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 engine starts NOTICE Operating the vehicle immediately aft...

Page 82: ...tion key to prevent unauthorized use COLD WEATHER OPERATION If the vehicle 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 the crankcase can lead to engine damage and must be drained Water accumulation increases as outside temperature decreases See...

Page 83: ...driving experience with the vehicle 3 Never allow anyone under 12 years of age to ride as a passenger on a 2 up ATV Make sure any passenger is tall enough to comfortably and safely reach the grab handles and footrests 4 Make sure the passenger is wearing appropriate riding gear including an approved helmet with a rigid chin guard 5 Perform the pre ride inspection 6 Lock the parking brake 7 Mount t...

Page 84: ...quipped with a solid rear axle which drives both rear wheels equally at all times This means that the wheel on the outside of the turn must travel a greater distance than the inside wheel when turning and the inside tire must slip traction slightly 1 Slow down 2 Never turn quickly when carrying a passenger or cargo 3 Steer in the direction of the turn 4 Keep both feet on the footrests 5 Lean your ...

Page 85: ...clude dismounting quickly 9 Never open the throttle suddenly or make sudden gear changes 10 Never go over the top of a hill at high speed If all forward speed is lost 1 Keep your weight uphill A passenger should also lean uphill 2 If the vehicle begins rolling downhill never apply engine power Never apply the brakes aggressively while rolling backwards 3 Apply the brakes gradually When fully stopp...

Page 86: ...E Severe damage to drive train may occur if the 4X4 is engaged while the wheels are spinning Allow the rear wheels to stop spinning before engaging 4X4 or engage 4X4 before wheels begin to lose traction 4 Maintain a high level of alertness reading the trail and avoiding quick sharp turns which can cause skids 5 Never apply the brakes during a skid Correct a skid by turning the handlebars in the di...

Page 87: ...h the transmission in forward gear Do not descend a hill with the transmission in neutral 5 Never drive downhill at high speed Slow down 6 Drive straight downhill Avoid driving downhill at an angle which can cause the vehicle to pitch sharply to one side 7 Shift body weight uphill A passenger should also shift body weight uphill 8 Apply the brakes slightly to aid in slowing Applying the brakes too...

Page 88: ... 4 Avoid hills with slippery or loose surfaces 5 Avoid crossing the sides of steep hills 6 Do not cross a hillside with a passenger on board Ask the passenger to dismount and walk across the hillside before remounting the vehicle 7 If the vehicle begins to slide or tip quickly turn the front wheel downhill if possible or dismount on the uphill side immediately 86 OPERATION Downloaded from ManualsN...

Page 89: ...e the brake lever to release the parking brake 7 Slowly release the brake lever and allow the vehicle to roll around to your right until it s pointing across the hill or slightly downward 8 Lock the hydraulic parking brake 9 Remount from the uphill side Keep your weight uphill A passenger should not remount until the vehicle returns to firm level ground 10 Apply the foot brake 11 With the transmis...

Page 90: ...he vehicle tips or overturns in water or if the engine stops during or after operating in water restarting can result in serious engine damage Transport the vehicle to your dealer for service before restarting the engine If this is not possible follow the vehicle immersion inspection and drying procedures outlined in the PVT Drying section then see your dealer for service at the first opportunity ...

Page 91: ...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 not operate at wide open throttle Operate the throttle just enough to maintain a desired speed NOTICE Excessive throttle operation while in the speed limit mode may cause fuel to build in the exhaust resulting in engine popp...

Page 92: ...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 operate over large obstacles such as rocks or fallen trees 5 Always have a passenger dismount before operating over an obstacle that could cause a fall from the vehicle or vehicle tipover 90 OPERATION Downloaded from ManualsN...

Page 93: ...line 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 91 OPERATION Downloaded from ManualsNet com search engine ...

Page 94: ...LOADS AS LOW ON THE RACKS AS POSSIBLE Carrying loads high on the racks 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 result in loss of control of the vehicle OPERATE ONLY WITH STABLE AND SAFELY ARRANGED LOADS When handling off centered loads that cannot...

Page 95: ...dels NEVER exceed 16 km h when rear cargo loads are above 91 kg Make sure the cargo box dump latch is securely latched before loading and operating Unintentional dumping will result if weight is placed in the rear of the box and the latch is not secured 6 When operating over rough or hilly terrain reduce speed and cargo weight to maintain stable driving conditions 7 Do not obstruct the headlight b...

Page 96: ...ous damage to the vehicle and will void your warranty Never install a hitch longer than 13 cm Never install automotive accessories on your POLARIS Tractor Always install POLARIS approved or equivalent accessories designed for Tractor use DUMPING CARGO X2 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 alw...

Page 97: ...re the release latch is secured 9 Secure the tailgate WARNING Driving 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 driver The rear tires will also catch the rear of the bed damaging the vehicle and creating hazardous driving conditions Never drive this vehicle with the cargo box in the raised posi...

Page 98: ...ssion into neutral for better mobility and to prevent damage to the belt Always attach the tow cable to the front tow loop of the disabled Tractor A rider must be on board to steer the disabled Tractor while towing 96 OPERATION Downloaded from ManualsNet com search engine ...

Page 99: ... 3 Secure the fuel cap oil cap and seat 4 Remove the key to prevent loss during transporting 5 Always tie the frame of the Tractor to the transporting unit securely with suitable straps or rope Do not attach tie straps to the front A arm bolt pockets racks or handlebars 97 OPERATION Downloaded from ManualsNet com search engine ...

Page 100: ...98 Downloaded from ManualsNet com search engine ...

Page 101: ...e 107 7 Always keep the area around the vehicle winch winch cable and load clear of people especially children and distractions while operating the winch 8 Always turn the vehicle ignition power OFF when it and the winch are not being used 9 Always be sure that at least five 5 full turns of winch cable are wrapped around the winch drum at all times The friction provided by this wrapped cable allow...

Page 102: ...let the winch cable run through your hands even if wearing heavy gloves 18 Never release the clutch on the winch when the winch cable is under load 19 Never use the winch for lifting or transporting people 20 Never use the winch to hoist or suspend a vertical load 21 Never immerse or submerse your winch in water Your dealer can provide service on your winch if this occurs 22 Always inspect your wi...

Page 103: ...working Always remember that your winch is very powerful There are simply some situations that you and your winch will not be able to deal with Do not be afraid to ask others to help when this happens 1 Always inspect the vehicle winch winch cable and winch controls for any signs of damage or parts in need of repair or replacement before each use Pay particular attention to the first 3 feet 1 mete...

Page 104: ...the hook This could lead to SEVERE INJURY Attach the hook itself onto the load or use a tow strap or chain to secure the load to the winch cable TIP A tow strap is NOT intended to stretch A recovery strap is designed to stretch 102 WINCH GUIDE Downloaded from ManualsNet com search engine ...

Page 105: ...and reduce the load on the fairlead If freeing a stuck vehicle by attaching to a tree use an item such as a tow strap to avoid damaging the tree during winch operation Sharp cables and chains can damage and even kill trees Please remember to Tread Lightly treadlightly org Before operating the winch be sure that the safety latch on the winch cable hook is fully seated when the load is attached Neve...

Page 106: ...le failure 10 Never use straps chains or other rigging items that are damaged or worn 11 The ONLY time a winch equipped vehicle should be moving when using the winch is when that vehicle itself is stuck The winch equipped vehicle should NEVER be in motion to shock load the winch cable in an attempt to move a second stuck vehicle See the Shock Loading section on page 107 For your safety always foll...

Page 107: ... complete especially if winching at an angle it may be necessary to re distribute the winch cable across the winch drum You will need an assistant to perform this task a Release the clutch on the winch b Feed out the winch cable that is unevenly bunched up in one area c Re engage the winch clutch d Have an assistant pull the winch cable tightly with about 100 lbs 45 kg of tension using the hook st...

Page 108: ...t has been straightened out is shown at right Even though it may look usable the cable has been permanently and severely damaged It can no longer transmit the load that it could prior to kinking Promptly discontinue use of a winch cable in this condition A winch cable made of synthetic rope should be inspected for signs of fraying Replace the cable if fraying is observed shown below Promptly disco...

Page 109: ...winch cable and generates excessive heat from the motor This is a form of shock loading 3 Never tow a vehicle or other object with your winch Towing an object with a winch produces shock loading of the cable even when towing at slow speeds Towing from a winch also positions the towing force high on the vehicle This can cause instability of the vehicle and possibly lead to an accident 4 Never use r...

Page 110: ...place 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 wire rope as the winch cable Other winches use a specially designed synthetic rope as the winch cable 6 Never replace a synthetic rope winch cable with a consumer grade polymer rope such as can be purchased in a hardware ...

Page 111: ... with active or non active implantable medical devices such as heart monitoring or controlling devices should review the limitations of their device and the applicable electromagnetic standards and directives that apply to this vehicle CARBON DIOXIDE CO2 EMISSION Carbon dioxide CO2 emission 1235 g kWh This CO2 measurement results from testing over a fixed test cycle under laboratory conditions a n...

Page 112: ...s Ear 91 dB C uncertainity 3dB A Weighted Sound Power Level n a Vibration Weighted Hand Arm Vibration Level 4 1 m s 2 5 m s Weighted Seat Vibration Level 0 6 m s 0 5 m s 110 EMISSION CONTROL SYSTEMS Downloaded from ManualsNet com search engine ...

Page 113: ... these operations Maintenance intervals in the following chart are based upon average riding conditions and an average vehicle speed of approximately 16 kilometers per hour 10 mph Vehicles subjected to severe use must be inspected and serviced more frequently SEVERE USE DEFINITION Frequent immersion in mud water or sand Frequent or prolonged operation in dusty environments Short trip cold weather ...

Page 114: ...ack This vehicle is not equipped with dedicated jacking points Place the floor jack at the front or rear of the vehicle directly under the center of the unit Make sure the floor jack makes contact only with the frame of the vehicle while lifting q Do not allow the vehicle to remain elevated on a floor jack After elevating place jack stands under the frame on each side of the floor jack then lower ...

Page 115: ...e Maintenance Log ITEM MAINTENANCE INTERVAL WHICHEVER COMES FIRST REMARKS HOURS CALENDAR MILES KM Steering Pre Ride Inspect and make adjustments as needed Front Suspension Rear Suspension Tires Brake Fluid Level Brake Lever Travel Brake System Wheels Fasteners CV Boot Frame Fasteners Engine Oil Level Winch if equipped XU Air Filter Pre Filter Daily Inspect clean often replace as needed Coolant Dai...

Page 116: ... 500 800 Inspect D Steering 50 H 6 M 500 800 Lubricate XU Front Rear Suspension 50 H 6 M 500 800 Lubricate XU Throttle Release Switch if equipped 50 H 6 M 500 800 Inspect adjust lubricate replace if necessary Throttle Body Intake Duct 50 H 6 M 500 800 Inspect ducts for proper sealing air leaks Drive Belt 50 H 6 M 500 800 Inspect replace as needed XU Air Filter main element 50 H 6 M 500 800 Inspect...

Page 117: ...s needed XU Wiring 100 H 12 M 1000 1600 Inspect for wear routing security apply dielectric grease to connectors 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 2000 3200 Change every two years Spark Arrestor 300 H 36 M 3000 4800 Clean out or remove clean...

Page 118: ...G TORQUE REF Engine Oil PS 4 5W 50 4 Cycle Oil 1 9 l 2 qt 19 23 Nm 14 17 ft lbs page 117 Brake Fluid DOT 4 Brake Fluid page 126 Transmis sion Oil AGL Gearcase Lubricant Transmission Fluid 946 ml 32 oz 27 34 Nm 20 25 ft lbs 27 34 Nm 20 25 ft lbs page 121 Demand Drive Fluid Front Gearcase Demand Drive Fluid 275 ml 9 3 oz 11 14 Nm 8 10 ft lbs 15 Nm 11 ft lbs page 122 Rear Gearcase Oil ATV Angle Drive...

Page 119: ...ccelerated wear and may result in engine seizure accident and injury Always perform the maintenance procedures as outlined in the Periodic Maintenance Chart OIL RECOMMENDATIONS Always change the oil filter whenever changing oil POLARIS recommends the use of POLARIS PS 4 Full Synthetic 5W 50 4 cycle oil or a similar oil for this engine Oil may need to be changed more frequently if POLARIS oil is no...

Page 120: ... the right side of the ATV q Remove the dipstick Wipe it dry with a clean cloth 3 Reinstall and tighten the dipstick 4 Remove the dipstick and check the oil level 5 Add the recommended fluid as needed Maintain the oil level in the safe range between the FULL and ADD marks Do not overfill 6 Reinstall and tighten the dipstick 118 MAINTENANCE Downloaded from ManualsNet com search engine ...

Page 121: ...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 drain completely CAUTION Hot oil can cause burns to skin Do not allow hot oil to contact skin 7 Install a new sealing washer on the drain plug The sealing surfaces on drain plug and crankcase should be clean and free of burrs ni...

Page 122: ... 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 gasket contacts the sealing surface then turn it an additional 3 4 turn 5 Remove the dipstick 6 Add the proper amount of the recommended oil Do not overfill 7 Reinstall the dipstick 8 Place the transmission in PARK 9 Lock the parki...

Page 123: ...lug 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 Reinstall the footwell OIL CHANGE TORQUE Drain Plug 20 25 ft lbs 27 34 Nm 1 Place a drain pan under the gearcase Remove the drain plug w Allow the oil to drain completely 2 Clean and reinstall the drain plug Torque to specific...

Page 124: ...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 of components Maintain the fluid level at the bottom of the fill hole threads The fill plug is located on the right side of the demand drive unit The drain plug is located on the bottom right side of the unit FLUID CHECK T...

Page 125: ...the radiator pressure cap and the connecting hose As coolant operating temperature increases the expanding heated excess coolant is forced out of the engine past the pressure cap and into the recovery bottle As engine coolant temperature decreases the contracting cooled coolant is drawn back up from the bottle past the pressure cap and into the radiator Some coolant level drop on new vehicles is n...

Page 126: ...he cooling 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 CAUTION Escaping steam can cause burns Never remove the pressure cap while the engine is warm or hot Always allow the engine to cool before removing the pressure cap 1 Access the pressure cap und...

Page 127: ...ll 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 Under normal operation the diaphragm extends into the reservoir as fluid level drops If the fluid level is low and the diaphragm is not extended a leak is likely and the diaphragm should be replaced To ensure proper diaphragm operation...

Page 128: ... are straight 2 View the fluid level through the indicator window eye w on the top of the master cylinder TIP The eye will appear dark when the fluid level is full e When fluid is low r the eye will be clear 3 If the fluid level is low remove the cover screws and add fluid to the fill line Do not overfill 4 Reinstall the cover Torque screws to 0 8 Nm 7 in lbs 126 MAINTENANCE Downloaded from Manual...

Page 129: ...on the vehicle on a level surface 2 Remove the seat 3 View the fluid level in the reservoir 4 Remove the cap and add the recommended fluid as needed 5 Maintain the fluid level between the minimum e and maximum w marks Do not overfill 6 Reinstall the reservoir cap 7 Reinstall the seat 127 MAINTENANCE Downloaded from ManualsNet com search engine ...

Page 130: ...vel 2 Check the brake systems regularly for fluid leaks 3 Check the brakes for excessive travel or spongy feel 4 Check the friction pads for wear damage and looseness Replace the pads when the friction material is worn to 0 762 mm 5 Check the security and surface condition of the disc Clean any grease using a recommended brake cleaner or alcohol Do not use spray lubricants or other petroleum based...

Page 131: ... the gas tank or any other part of the machine when turned fully to the left or right 5 Torque the front two bolts q to 14 17 Nm then torque the rear two bolts A gap of up to 3 mm will remain at the rear of the clamp blocks POWER STEERING UNIT If your model is equipped with power steering frequently clean the areas around and on the power steering unit to allow proper cooling Clean these areas tho...

Page 132: ...damage heat shield when removing the side panel To remove the side panel do the following 1 Remove the seat 2 Using the Polaris provided pliers in the tool kit remove the side panel rivets q 3 Grasp near the front by fuel tank and pull up on the side panel until clips disengage 4 Pull the panel outward and rearward to remove 130 MAINTENANCE Downloaded from ManualsNet com search engine ...

Page 133: ...es 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 and on the labels on the vehicle Always use original equipment size and type when replacing tires Refer to the specifications section for recommended tire type size and pressure TIRE TREAD DEPTH Always replace tires when tread dep...

Page 134: ...ALLATION 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 toward forward rotation if equipped 4 Install the wheel nuts and finger tighten them 5 Lower the vehicle to the ground 6 Torque the wheel nuts to specification WARNING Loose nuts could cause a tire to come off during operati...

Page 135: ...onally and when they ve been loosened for maintenance service Lug Nut Aluminum Wheels Front and Rear 30 ft lbs 41 Nm PLUS 1 4 TURN or 70 degrees 2 Piece Flange Nut Steel Wheels Front and Rear 27 ft lbs 37 Nm 133 MAINTENANCE Downloaded from ManualsNet com search engine ...

Page 136: ...a length of string between two stands as shown in the illustration 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 instead of string 4 Measure the distance from the string to the rim at the front q and rear w of the front rim The rear measurement should be 1 8 1 4 inch 3 6 mm more than the front measurement on each side o...

Page 137: ...eather valve is on the hose that runs between the engine and air box 1 Remove the left side panel 2 Remove the hose clamps from the valve and pull the valve out of the hoses 3 Inspect the valve for debris Blow gently through the valve to check for clogging Replace a damaged or clogged valve 4 Check the hoses for cracks deterioration abrasion or leaks Replace as needed 5 Reinstall the valve and hos...

Page 138: ...are fuses are provided in a compartment on the top of the access door 1 Open the front box cover 2 Remove the access panel 3 Remove fuse box cover 4 Remove the suspect fuse from the fuse panel q If the fuse is blown install a new fuse with the same amperage 5 Secure the fuse box cover and access panel 6 Secure the front box cover q Fuse Box w Labels Inside Box Cover 136 MAINTENANCE Downloaded from...

Page 139: ...e adjusted slightly upward or downward Use the following procedure to make the adjustment NOTE Image below is for reference only Your model may differ slightly 1 Position the vehicle on a level surface with the headlight approximately 25 ft 7 6 m from a wall q Place the transmission in PARK 2 Measure the distance from the floor to the center of the headlight and make a mark on the wall at the same...

Page 140: ...st the headlamp to the desired position then tighten the screw All Other Models 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 counter clockwise LOW BEAM ADJUSTMENT The low beam can be adjusted slightly upward or downward 1 Loosen the Phillips screw located at the rear of the headlamp 2 Tilt the ...

Page 141: ...dlamp q Phillips Screw w Lamp e Harness HEADLIGHT HOUSING REPLACEMENT 570 SP MODELS To replace the headlight housing do the following 1 Remove the seven 7 headlight pod screws 2 Pull the pod cover forward 3 Unplug the headlamp from the wiring harness 4 Use a small screwdriver to remove the o rings from the headlight mounting tabs 5 Pull the headlight housing up from bracket for removal 6 Reverse t...

Page 142: ...ewdriver 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 The distance from the headlamp parting line to the end of the adjustment knob stop...

Page 143: ... transmission in PARK 2 Reach under the front bumper area to locate the lighting connectors 3 Parking Light Lamp Disconnect the harness connector Turn the socket counter clockwise 1 8 turn and remove the lamp assembly Pull the lamp straight out to remove it from the socket 4 Headlight Lamp Disconnect the harness connector Remove the rubber cover from the back of the headlight Press and turn the lo...

Page 144: ...ONT TURN SIGNAL REPLACEMENT If a front turn signal light becomes inoperable the lamps cannot be replaced Replace the entire signal lamp assembly REAR TURN SIGNAL LAMP REPLACEMENT SPORTSMAN 1 Place the transmission in PARK 2 Rotate the turn signal socket counter clockwise to remove it 3 Remove the lamp 4 Apply dielectric grease to the socket 5 Install the new lamp Test the lamp for proper operation...

Page 145: ... A hot exhaust system and engine can cause burns Wear protective gloves when removing a spark plug for inspection NORMAL SPARK PLUG The normal insulator tip is gray tan or light brown There will be few combustion deposits The electrodes are not burned or eroded This indicates the proper type and heat range for the engine and the service The tip should not be flaky and white A white insulator tip i...

Page 146: ...er before starting the engine If it s impossible to take your ATV to a dealer before starting it follow the steps outlined below 1 Move the ATV to dry land or at the very least to water below the footrests 2 Check the air box If water is present dry the air box and replace the filter with a new filter 3 Remove the spark plug 4 Turn the engine over several times using the electric start 5 Dry the s...

Page 147: ...otection Do not stand behind or in front of the vehicle while purging the carbon from the spark arrestor Never run the engine in an enclosed area Exhaust contains poisonous carbon monoxide gas Do not go under the machine while it is inclined Set the hand brake and block the wheels to prevent roll back Failure to heed these warnings could result in serious personal injury or death The exhaust pipe ...

Page 148: ... The PVTsystem has been precision balanced Any modification will cause the system to be out of balance creating vibration and additional loads on components The PVTsystem 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...

Page 149: ... a level surface 2 Remove the drain plug Allow the water to drain completely Reinstall the drain plug 3 Start the engine Place the transmission in PARK 4 Apply varying throttle for 10 15 seconds to expel the moisture and air dry the belt and clutches Do not hold the throttle wide open for more than 5 seconds 5 Allow the engine RPM to settle to idle speed then shift the transmission to low range 6 ...

Page 150: ...eep sparks flame cigarettes etc away Ventilate when charging or using in an enclosed space Always shield eyes when working near batteries KEEP OUT OF REACH OF CHILDREN Your vehicle may have either a sealed battery which requires little maintenance or a conventional battery A sealed battery can be identified by its flat covers on the top of the battery A conventional battery has six filler caps on ...

Page 151: ...resulting in serious injury or death Always ensure that the vent tube is free of obstructions and is securely installed as recommended 1 Ensure that the battery is fully charged 2 Place the battery in the battery holder 3 With conventional batteries install the battery vent tube sealed batteries do not have a vent tube The vent tube must be free of obstructions and securely installed Route the tub...

Page 152: ...yte BATTERY STORAGE Whenever the vehicle is not used for a period of three months or more remove the battery from the vehicle ensure that it s fully charged and store it out of the sun in a cool dry place Check battery voltage each month during storage and recharge as needed to maintain a full charge POLARIS recommends maintaining battery charge by using a POLARIS Battery Tender charger or by char...

Page 153: ...RY The following battery charging instructions apply only to the installation of a sealed battery Read all instructions before proceeding with the installation of this battery The sealed battery is already filled with electrolyte and has been sealed and fully charged at the factory Never pry the sealing strip off or add any other fluid to this battery The single most important thing about maintain...

Page 154: ... verify battery condition before and 1 2 hours after the end of charging STATE OF CHARGE VOLTAGE ACTION CHARGE TIME 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 ...

Page 155: ...arts last 2 Rinse with clean water frequently 3 Dry surfaces with 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 wi...

Page 156: ...rosion preserve wheel life and ensure a like new appearance for many years Chrome wheels exposed to road salt or salt in the air in coastal areas are more susceptible to corrosion if not properly cleaned Clean chrome wheels more often if they re exposed to salt or other corrosive elements 1 Wash chrome wheels frequently Use a mild detergent Never use abrasive cleaners on plated or painted surfaces...

Page 157: ...ms stabilizes fuel and removes carbon deposits from pistons rings valves and exhaust systems 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 the Engine Oil section AIR FILTER AIR BOX 1 Inspect and clean or replace the pre cleaner and air filter See the Air Filter section 2 Clean the...

Page 158: ...e film of fresh oil 6 Reinstall the spark plug caps 7 If POLARIS fuel system additive is not used fuel tank fuel lines and injectors should be completely drained of gasoline INSPECT AND LUBRICATE Inspect all cables and lubricate all areas of the vehicle as recommended in the Periodic Maintenance Chart BATTERY MAINTENANCE Remove the battery and recharge it as outlined in the Battery Charging sectio...

Page 159: ...l Width 122 cm Overall Height 122 cm Wheelbase 142 3 cm Ground Clearance 28 cm Minimum Turning Radius 165 cm unloaded Fuel Capacity 25 5 l Engine Oil Capacity 1 9 l Coolant Capacity 2 5 l Demand Drive Fluid Capacity 275 ml Transmission Oil Capacity 948 ml Engine Dual overhead cam 4 valve 4 stroke single cylinder Displacement 567 cc Bore x Stroke 99mm x 73 6mm Alternator Output 660 W 7000 RPM Compr...

Page 160: ...ires Pressure Front 25x8 12 48 3 kPa 4 83 bar 63 5 PSI Tires Pressure Rear 25x11 12 48 3 kPa 4 83 bar 63 5 PSI Brake Hand Single Control Hydraulic Disc Brake Foot Foot Activated Hydraulic Disc Brake Parking Transmission park lock and hydraulic lock all wheel Winch Front permanent Installed winch with 2500 Lbs 1125 Kg Capacity Headlight 2 dual beam on bumper 55 60 watt 1 single beam on headlight po...

Page 161: ...kg operator cargo accessories Dry Weight 7 based on configuration 354 kg Front Rack Box Capacity 41 kg Rear Rack Cargo Box Capacity 181 kg Unbraked Trailer Mass 270 kg Braked Trailer Mass 830 kg Overall Length 228 cm Overall Width 122 cm Overall Height 122 cm Wheelbase 142 3 cm Ground Clearance 28 cm Minimum Turning Radius 165 cm unloaded Fuel Capacity 25 5 l Engine Oil Capacity 1 9 l Coolant Capa...

Page 162: ...with 21 cm travel Rear Suspension Progressive rate with 24 cm travel Transmission H L N R P Gear Reduction Low 23 91 1 Gear Reduction Reverse 21 74 1 Gear Reduction High 10 57 1 Drive Ratio Front 3 25 1 Tires Pressure Front 25x8 12 48 3 kPa 4 83 bar 63 5 PSI Tires Pressure Rear 25x11 12 48 3 kPa 4 83 bar 63 5 PSI Brake Hand Single Control Hydraulic Disc Brake Foot Foot Activated Hydraulic Disc Bra...

Page 163: ...s 8 26 watts Brake Light 26 9 watts Instrument Cluster LCD Noise by ear dB A 79 dB Noise in motion 81 8 dB CLUTCHING CHART ALTITUDE IN METERS FEET SHIFT WEIGHT DRIVE CLUTCH SPRING DRIVEN CLUTCH SPRING HELIX 0 3700 0 12000 25 52G PN 5632409 Black PN 7043594 Red PN 7041782 EBS PN 3235639 161 SPECIFICATIONS Downloaded from ManualsNet com search engine ...

Page 164: ...EAT VIBRATION DRIVER MEAN WEIGHTED RMS SEAT ACCL AWS M S2 MEAN WEIGHTED RMS SEAT ACCL AWB M S2 RATIO AWS AWB Heavy 0 68 0 85 0 8 Light 0 82 0 89 0 9 162 SPECIFICATIONS Downloaded from ManualsNet com search engine ...

Page 165: ...ic Gearcase Lubricant Transmission Fluid 95 L 2878069 AGL Full Synthetic Gearcase Lubricant Transmission Fluid 3 8 L 2877922 Demand Drive Plus Fluid 95 L 2877923 Demand Drive Plus Fluid 3 8 L 2870465 Pump for 3 8 L Jug Coolant 2880514 Antifreeze 50 50 Premix 95 L 2880513 Antifreeze 50 50 Premix 3 8 L Grease Specialized Lubricants 2871312 Grease Gun Kit Premium All Season 2871322 All Season Grease ...

Page 166: ...871329 Dielectric Grease Nyogel Additives Miscellaneous 2871326 Carbon Clean 2870652 Fuel Stabilizer 2872189 DOT 4 Brake Fluid 2871956 Loctite 565 Thread Sealant 2859044 POLARIS Battery Tender Charger 164 POLARIS PRODUCTS Downloaded from ManualsNet com search engine ...

Page 167: ...ity use plowing Use low range only Stuck in mud or snow Shift the transmission to low range Carefully use fast aggressive throttle application to engage clutch WARNING Excessive throttle may cause loss of control and vehicle rollover Climbing over large objects from a stopped position Belt slippage from water or snow ingestion into the PVT system Dry out the PVT Inspect clutch seals for damage if ...

Page 168: ...nspect plug and replace if necessary Water or fuel in crankcase Your authorized dealer can assist Low battery voltage Recharge the battery to 12 8 VDC Mechanical failure Your authorized dealer can assist ENGINE BACKFIRES POSSIBLE CAUSE SOLUTION Weak spark from spark plug Inspect clean and or replace spark plug Incorrect spark plug gap or heat range Set gap to specs or replace plug Old or non recom...

Page 169: ...sist Incorrect spark plug gap or heat range Set gap to specs or replace plugs Loose ignition connections Check all connections and tighten Water present in fuel Replace with new fuel Low battery voltage Recharge battery to 12 8 VDC 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 lim...

Page 170: ... warm up before operating and or stopping Incorrect fuel Replace with recommended fuel Clogged air filter Inspect and clean or replace ENGINE STOPS OR LOSES POWER POSSIBLE CAUSE SOLUTION Out of fuel Refuel cycle key to ON position three times for 5 seconds each then start Kinked or plugged fuel vent line Inspect and replace Water is present in fuel Replace with new fuel Fouled or defective spark p...

Page 171: ...control malfunction Your authorized dealer can assist Other mechanical failure Your authorized dealer can assist Overheated engine Clean radiator screen and core clean engine exterior Your POLARIS dealer can assist ENGINE OVERHEATING POSSIBLE CAUSE SOLUTION Debris lodged in screen Clean the screen Plugged Radiator Use a garden hose to flush any debris from the radiator fins NOTE High pressure wash...

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Page 173: ...iginal term of the warranty The duration of this warranty may vary by international region based upon local laws and regulations REGISTRATION At the time of sale the Warranty Registration Form must be completed by your dealer and submitted to POLARIS within ten days of purchase Upon receipt of this registration POLARIS will record the registration for warranty No verification of registration will ...

Page 174: ...on improper maintenance modified components use of aftermarket or unapproved components accessories or attachments use of unapproved software or calibration unauthorized repairs or repairs made after the warranty period expires or by an unauthorized repair center This warranty excludes damages or failures caused by abuse accident fire or any other cause other than a defect in materials or workmans...

Page 175: ...O LIABILITY TO ANY PERSON FOR INCIDENTAL CONSEQUENTIAL OR SPECIAL DAMAGES OF ANY DESCRIPTION WHETHER ARISING OUT OF EXPRESS OR IMPLIED WARRANTY OR ANY OTHER CONTRACT NEGLIGENCE OR OTHER TORT OR OTHERWISE THIS EXCLUSION OF CONSEQUENTIAL INCIDENTAL AND SPECIAL DAMAGES IS INDEPENDENT FROM AND SHALL SURVIVE ANY FINDING THAT THE EXCLUSIVE REMEDY FAILED OF ITS ESSENTIAL PURPOSE THE IMPLIED WARRANTY OF F...

Page 176: ...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 If you move to another country be sure to contact POLARIS Customer Assistance and the customs department of the destination country before you move Product importation rules vary considerably from country to country You may...

Page 177: ...dure 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 officials or military personnel on assignment outside of the country where the product was purchased will continue to be covered by the Limited Warranty Please work with your dealer to resolve any warranty issues Dealership conta...

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Page 179: ...ENANCE LOG MAINTENANCE LOG Use the following chart to record periodic maintenance DATE MILES KM OR HOURS TECHNICIAN SERVICE PERFORMED COMMENTS 177 MAINTENANCE LOG Downloaded from ManualsNet com search engine ...

Page 180: ...178 Downloaded from ManualsNet com search engine ...

Page 181: ...n a 2 Up ATV 15 Chrome Wheel Care 154 Clean the Exterior 155 Clothing 13 Clutch Cover Alert 29 33 Clutching Chart 159 161 Cold Weather Operation 80 Cooling System 123 Crossing Hillsides 19 Crush Alerts 34 D Descending Hills Improperly 18 Diagnostic Display Code Definitions 68 Drive Belt Wear Burn 165 Driveline Mode Switch 40 Driver s Seat Vibration 162 Driving Downhill 85 Driving in Reverse 89 Dri...

Page 182: ...ng Cargo 92 Hazard Warning Switch 40 Headlight and Momentary High Beam Switch 39 Headlight Housing Replacement 140 Headlight Housing Replacement 570 SP Models 139 Headlight Parking Light Lamp Replacement 141 Helmet 13 High Beam Adjustment 137 Hill Operation Alert 7181536 29 33 Hitch Removal Installation 51 Hitches 50 Horn Switch 40 How To Obtain Warranty Service 174 I Improper Cargo Loading 21 Imp...

Page 183: ...g Without Instruction 14 Override Alert 7181544 28 32 P Parking Brake 45 Parking on an Incline 91 Parking the Vehicle 80 Passenger Seat Backrest Touring 48 Periodic Maintenance 111 Severe Use Definition 111 Physical Control of the ATV 16 Polishing the Vehicle 154 Poor Visibility 23 Power Steering Unit 129 Pre Ride Checklist 77 Protective Apparel 15 PVT Break in Clutches Belt 76 PVT Drying 147 PVT ...

Page 184: ...94 Towing the Tractor 96 Trademarks 2 Trailering the Tractor 97 Transmission Oil 121 TURF Mode 54 Turn Signal Switch 39 Turning Around on a Hill K Turn 87 Turning Improperly 17 Turning the Vehicle 82 U Unauthorized Use of the Vehicle 25 V Variable Low Speed Switch 40 Vehicle Break in Period 75 Vehicle Identification Numbers 9 Vehicle Immersion 144 W Warning Symbols 8 Washing the Vehicle 153 Welcom...

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Page 186: ...For your nearest Polaris dealer visit www polaris com Polaris Sales Europe Sarl Place de l Industrie 2 1180 Rolle Switzerland Part No 9939859 Rev 01 Downloaded from ManualsNet com search engine ...

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