Polaris Sportsman X2 850 Page 57 Owner'S Manual For Maintenance And Safety Download

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FEATURES AND CONTROLS

Instrument Cluster

Diagnostic Display Code Definitions

*Assumes unipolar configuration of stepper motor

Sportsman 550 X2 Diagnostic Codes

Component

Condition

SPN

FMI

Throttle Position Sensor

Voltage Too High

Voltage Too Low

Engine Temperature Sensor

Voltage Too High

110

Voltage Too Low

110

Temperature Too High

110

Engine Overheat Shutdown

110

Intake Air Temperature Sensor

Voltage Too High

105

Voltage Too Low

105

Manifold Absolute Pressure Sensor

Voltage Too High

102

Voltage Too Low

102

Crankshaft Position Sensor

Circuit Fault

636

Gear Sensor Signal

Voltage Too Low (to Calibrate)

523

Voltage Too High

523

Signal Fault

523

Injector 1 (MAG)

Driver Circuit Open/Grounded

651

Driver Circuit Short to B+

651

Ignition Coil Primary Driver 1 (MAG)

Driver Open/Grounded

1268

Driver Circuit Short to B+

1268

Fuel Pump Driver Circuit

Driver Circuit Open/Grounded

1347

Driver Circuit Short to B+

1347

Fan Relay Driver Circuit

Driver Circuit Open/Grounded

1071

Driver Circuit Short to B+

1071

Idle Air Control

Driver Circuit Grounded

520193

Shorted Load*

520193

Starter Enable Circuit

Driver Circuit Short to B+

1321

All Wheel Drive Control

Driver Circuit Short to B+

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

Throttle Stuck

520194

Summary of Contents for Sportsman X2 850

Page 1: ...l carefully 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 X2 850 Sp...

Page 2: ...r s manual on the next page If you cannot locate this card or if it has been removed please call 1 800 342 3764 for assistance WARNING The engine exhaust from this product contains chemicals known to...

Page 3: ...The text is printed on 100 recycled with 40 post consumer waste PCW...

Page 4: ...H DRUGS OR ALCOHOL without proper ATV training or instruction at speeds too fast for your skills or the conditions on public roads a collision can occur with another vehicle with a passenger unless pa...

Page 5: ...any years of experience have gone into the engineering design and development of your POLARIS vehicle making it the finest machine we ve ever pro duced For safe and enjoyable operation of your vehicle...

Page 6: ...ult between the actual vehicle and the information presented in this publi cation Depictions and or procedures in this publication are intended for reference use only No liability can be accepted for...

Page 7: ...TENTS Introduction 4 Safety 7 Features and Controls 28 Operation 54 Emission Control Systems 80 Maintenance 81 Troubleshooting 133 POLARIS Products 137 Specifications 138 Warranty 142 Maintenance Log...

Page 8: ...ituation that if not avoided will result in death or serious injury WARNING A WARNING indicates a hazardous situation that if not avoided could result in death or serious injury CAUTION A CAUTION indi...

Page 9: ...ration is prohibited for anyone under 16 years of age Never permit a guest to operate the ATV unless the guest has read this manual and all product labels and has completed a certified safety training...

Page 10: ...keys The ignition switch must be replaced if all keys are lost The manufacturer s label is located on the front right side of the vehicle behind the radiator Vehicle Model Number ____________________...

Page 11: ...iderCoursesm for a fee Call ATV Enrollment Express at 800 887 2887 or visit www atvsafety org If you purchased a POLARIS ATV outside the United States please contact your dealer or local law enforceme...

Page 12: ...er on approved models should wear a helmet that includes a rigid chin guard Approved helmets in the USA and Canada bear a U S Department of Transportation DOT label Approved helmets in Europe Asia and...

Page 13: ...protect arms and legs Rid ing pants with kneepads and a jersey with shoulder pads provide the best protection Equipment Modifications We strongly recommend that consumers do not install on a POLARIS A...

Page 14: ...nt types of terrain Beginning and inexperienced operators should complete the recommended safety training before operating this vehicle See page 7 Never permit a guest to operate the ATV unless the gu...

Page 15: ...ange clothing Exposure to Exhaust Engine exhaust fumes are poisonous and can cause loss of consciousness or death in a short time Never start the engine or let it run in an enclosed area The engine ex...

Page 16: ...carry a passenger until you have at least two hours of driving experience with this vehicle Carrying More Than One Passenger Carrying more than one passenger greatly reduces the operator s ability to...

Page 17: ...Avoid operating the ATV on pavement ATV tires are designed for off road use If it s unavoidable travel slowly and avoid sudden turns or stops Operating on Public Roads Operating this ATV on public st...

Page 18: ...should always be seated in the passenger seat with both feet on the footrests and both hands on the passenger grab handles at all times The passenger should never hold on to the operator Turning Impr...

Page 19: ...manual See page 69 Always descend a hill with the transmission in forward gear Do not descend a hill with the transmission in neutral Never operate in TURF mode while operating on a hill or other irr...

Page 20: ...then the operator may dismount Turn the ATV around and remount following the procedure described in the owner s manual See page 70 If the ATV begins rolling backwards Keep operator and passenger body...

Page 21: ...n Failure to use extra caution when operating on unfamiliar terrain could result in an accident or overturn Unfamiliar terrain may contain hidden rocks bumps or holes that could cause loss of control...

Page 22: ...stacles could cause loss of control or overturn Before operating in a new area check for obstacles Avoid operating over large obstacles such as rocks and fallen trees If unavoidable use extreme cautio...

Page 23: ...pads Improper Cargo Loading Overloading the ATV or carrying towing cargo improperly may cause changes in handling which could cause loss of control or an accident Never exceed the stated load capacit...

Page 24: ...urrents may result in uneven ice thickness Always check with local authorities and residents to confirm ice conditions and thickness over your entire route ATV operators assume all risk associated wit...

Page 25: ...increased risk of overturn and loss of control Never secure a passenger to the vehicle or to the operator with a belt rope or similar device Hot Exhaust Systems Exhaust system components are very hot...

Page 26: ...HELMET AND PROTECTIVE GEAR FOR DRIVER AND PASSENGER NEVER USE ON PUBLIC ROADS NEVER CARRY MORE THAN 1 PASSENGER NEVER USE WITH DRUGS OR ALCOHOL NEVER operate without proper ATV training or instructio...

Page 27: ...arning AWD Caution 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 Always apply throttle grad...

Page 28: ...S use an approved helmet and protective gear securely grasp hand holds and plant feet firmly on footrests while seated in the passenger seat tell operator to slow down or stop if uncomfortable get off...

Page 29: ...verloading can cause loss of control Loss of control can result in severe injury or death Cold tire pressure Front 7 0 psi 48 3 kPa Rear 7 0 psi 48 3 kPa Maximum weight capacity 735 lbs 333 kg Lug nut...

Page 30: ...P Moving parts hazard under belt clutch guard To prevent serious injury do not operate vehicle with guard removed Do not modify engine or clutch Doing so can cause part failure possible imbalance and...

Page 31: ...ns Box Warning WARNING Remove flammable material containers from box before filling WARNING Passengers can be thrown off This can cause serious injury or death Never carry passengers in cargo box Maxi...

Page 32: ...as a MODE button when held down for approximately one half second See the instrument cluster information beginning on page 44 Tip The override button will not function as a MODE button if the transmis...

Page 33: ...mode See pages 38 39 The vehicle automatically engages 4X4 when operating in reverse if the switch is set to either 4X4 position Headlight Switch Use the headlight switch to turn the lights on and of...

Page 34: ...o the throttle release switch 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...

Page 35: ...the brake lever toward the handlebar 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 a...

Page 36: ...lead to early brake fade and the possibility of brake failure which could result in an accident After opening a bottle of brake fluid always discard any unused portion Check the brake fluid in the mas...

Page 37: ...unlocked position WARNING Operating the ATV while the parking brake is engaged could result in an accident or fire Always check to be sure the parking brake is disengaged before operating The parking...

Page 38: ...loss of control and serious injury or death The auxiliary brake system is intended to be used as a backup for the main brake system Should the main system fail use the aux iliary foot brake Since this...

Page 39: ...liary brake system The reservoir is located under the front storage box See page 43 Maintain the fluid level between the maximum and minimum marks Use DOT 4 brake fluid only NOTICE Do not use ADC flui...

Page 40: ...dling move the lever to the desired gear NOTICE Shifting gears with the engine speed above idle or while the vehicle is moving could cause transmission damage Whenever the ATV is left unattended alway...

Page 41: ...o allow for the normal expansion of fuel Do not overfill Do not fill the tank neck Extreme Use 30 AH Battery If your factory installed 18 AH battery cannot maintain a charge because of operation in ex...

Page 42: ...ing a hill See page 40 4X4 Mode When the switch is on 4X4 the ATV is in 4X4 and the 4X4 indica tor light in the instrument cluster will be on When in 4X4 the demand drive unit will automatically engag...

Page 43: ...rol and result in serious injury or death One rear wheel may slip and lose traction or may lift up and grab when it touches the ground again Engaging 4X4 The 4X4 switch may be turned on or off while t...

Page 44: ...ollow ing conditions occur The 4X4 switch must be in the ADC 4X4 position Vehicle speed must be 15 mph 24 km h or less The throttle must be closed throttle lever released The transmission must be in g...

Page 45: ...the seat to the 1 up position for single rider operation Never carry cargo in the rear box when operating the ATV in the 2 up mode with a passenger Seat Conversion 1 Make sure the cargo box dump latc...

Page 46: ...ns 6 Lower the operator backrest to create the passenger seat Two retaining pins under the seat should fit into the two grommets on the seat base 7 Test the passenger seat lock out by attempting to re...

Page 47: ...e rack illustration Posi tion the front edge in the tabs then push the box downward and secure the latches Access the following components in the front compartment Radiator cap Brake fluid reservoir A...

Page 48: ...he speedometer lens and other plastic surfaces Do not use alcohol to clean the instrument cluster Do not allow insect sprays to contact the lens Immediately clean off any gasoline that splashes on the...

Page 49: ...ated engine If the indicator stops flashing but remains illuminated the overheating condition remains and the system will automatically reduce engine power Neutral This lamp illuminates when the trans...

Page 50: ...cluster fails to illuminate a battery over voltage may have occurred and the instrument cluster may have shut off to protect the electronic speedome ter If this occurs take the ATV to your POLARIS dea...

Page 51: ...isplay This area displays odometer trip meter engine hour meter engine speed and programmable service hour interval 4 Active Descent Control Display This icon displays when ADC is active See page 40 5...

Page 52: ...d or metric units of measurement Tip To exit the set up mode at any time wait 10 seconds The display automati cally exits and returns to the odometer display 1 Turn the key to the OFF position 2 Place...

Page 53: ...Release the button 5 Repeat steps 3 4 twice to set the 10 minute and 1 minute segments After completing the 1 minute segment step 4 will save the new settings and exit the clock mode 6 Turn the key to...

Page 54: ...button 3 When the service hours flash press and release the MODE button to advance the hours to the desired setting including OFF Press and hold the MODE button to set the new service hour interval Di...

Page 55: ...e dis play Please see your Polaris dealer for all major repairs 1 If the error codes are not displayed use the MODE button to toggle until Ck ENG displays on the main line of the display 2 Press and h...

Page 56: ...e item has failed Short to Ground The wire is shorted to ground between the electronic control unit and the item listed in the chart Shorted Load The wires leading to the item listed in the chart are...

Page 57: ...age Too Low to Calibrate 523 4 Voltage Too High 523 3 Signal Fault 523 2 Injector 1 MAG Driver Circuit Open Grounded 651 5 Driver Circuit Short to B 651 3 Ignition Coil Primary Driver 1 MAG Driver Ope...

Page 58: ...Signal fault 523 2 Injector 1 MAG SDI Part Load Driver Circuit Open Grounded 651 5 Driver Circuit Short to B 651 3 Driver Circuit Grounded 651 4 Injector 2 PTO SDI Part Load Driver Circuit Open Ground...

Page 59: ...Driver Circuit Open Grounded 520207 5 Driver Circuit Short to B 520207 3 Driver Circuit Grounded 520207 4 System Power Voltage Too High 168 3 Voltage Too low 168 4 Throttle Safety Signal Voltage Too...

Page 60: ...POLARIS ATV is the first 25 hours of operation No single action on your part is as important as following the procedures for a proper break in Careful treatment of a new engine and drive components wi...

Page 61: ...ecks on fluid levels controls and areas outlined on the daily pre ride inspection checklist See page 58 6 Pull only light loads 7 Change both the oil and the filter at 25 hours 8 Check fluid levels of...

Page 62: ...teering Ensure free operation Tires Inspect condition and pressure 104 Wheels fasteners Inspect ensure fastener tightness 104 105 Frame nuts bolts fasteners Inspect ensure tightness Fuel and oil Ensur...

Page 63: ...a manner appropriate for your skills your passenger s skills and operating conditions Never operate at excessive speeds Never attempt wheelies jumps or other stunts Never remove your hands from the h...

Page 64: ...icle 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 terrain avoid littering and alwa...

Page 65: ...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 Repea...

Page 66: ...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 determin...

Page 67: ...the direction of the turn 4 Keep both feet on the footrests 5 Lean your upper body to the inside of the turn while supporting your weight on the outer footrest This technique alters the balance of tr...

Page 68: ...ways make sure the passenger seat lock out is functioning properly before carrying a passenger 6 Lock the parking brake 7 Mount the vehicle from the left side After the operator is seated the passenge...

Page 69: ...r hold on to the operator Never secure a passenger to the vehicle or to the operator with a belt rope or similar device 14 Make sure the passenger understands the importance of active rid ing When hil...

Page 70: ...traction NOTICE 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...

Page 71: ...ximum 4 Always check the terrain carefully 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 A pass...

Page 72: ...ow these precautions 1 Slow down 2 Avoid crossing the side of a steep hill 3 Do not cross a hillside with a passenger on board Ask the passenger to dismount and walk across the hillside before remount...

Page 73: ...descend a hill with the transmission in forward gear Do not descend a hill with the transmission in neutral 4 Slow down Never travel down a hill at high speed 5 Drive straight downhill Avoid traveling...

Page 74: ...70 OPERATION Turning Around on a Hill K Turn If the vehicle stalls while climbing a hill never back it down the hill Use the K turn to turn around 8 ft 2 4 m...

Page 75: ...the vehi cle or on the left if the vehicle is pointing straight uphill A passen ger should not remount until the vehicle returns to firm level ground 5 Staying uphill of the vehicle turn the handlebar...

Page 76: ...id and all grease fittings If the 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 y...

Page 77: ...onstantly alert for haz ards 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 at...

Page 78: ...turning at sharp angles 6 Never open 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 veh...

Page 79: ...an Incline Avoid parking on an incline if possible If it s unavoidable follow these precautions 1 Stop the engine 2 Place the transmission in PARK 3 Lock the parking brake 4 Always block the rear whee...

Page 80: ...operating conditions which could result in loss of control of the vehicle Always be sure that the cargo bed is lowered and latched before moving the vehicle USE EXTREME CAUTION when operating with loa...

Page 81: ...le carrying a passenger 6 NEVER exceed 10 MPH 16 km h when rear cargo loads are above 200 lbs 91 kg and or front cargo loads are above 100 lbs 45 kg 7 Always load the cargo box with the load as far fo...

Page 82: ...ight capacity of the vehicle NOTICE Using an improper hitch or exceeding the maximum tongue weight capacity can result in serious damage to the vehicle and will void your ATV warranty Never install a...

Page 83: ...ion the weight as far forward and as low as possible 6 Pull the cargo box release strap upward 7 Lift the front of the cargo box and dump the cargo 8 Lower the cargo box and make sure the release latc...

Page 84: ...rankcase system Blow by gases are forced back to the combustion chamber by the intake system All exhaust gases exit through the exhaust system Exhaust Emission Control System Exhaust emissions are con...

Page 85: ...m these operations Maintenance intervals in the following chart are based upon average rid ing conditions and an average vehicle speed of approximately 10 miles per hour Vehicles subjected to severe u...

Page 86: ...ons D Have an authorized POLARIS dealer perform these services Item Maintenance Interval whichever comes first Remarks Hours Calendar Miles Km Steering Pre Ride Make adjustments as needed See Pre Ride...

Page 87: ...ivots cables etc Shift linkage 50 H 6 M 500 800 Inspect lubricate D Steering 50 H 6 M 500 800 Lubricate Front suspension 50 H 6 M 500 800 Lubricate Rear suspension 50 H 6 M 500 800 Lubricate D E Throt...

Page 88: ...1600 Inspect D E Spark plug 100 H 12 M 1000 1600 Inspect replace as needed Wiring 100 H 12 M 1000 1600 Inspect for wear routing security apply dielectric grease to connectors subjected to water mud e...

Page 89: ...lbs 20 23 Nm Page 86 850 Engine Oil PS 4 PLUS Performance Synthetic 2W 50 2 qt 1 9 l 12 ft lbs 16 Nm Page 87 Transmission Oil AGL PLUS Transmission Fluid 37 oz 1100 ml 10 14 ft lbs 14 19 Nm 10 14 ft l...

Page 90: ...ndations capacities and plug torques Oil may need to be changed more frequently if POLARIS oil is not used Always use 2W 50 oil Follow the manufacturer s recommenda tions for ambient temperature opera...

Page 91: ...ipstick and fill tube from the left side of the ATV 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 reco...

Page 92: ...ngine Allow it to warm up at idle for two to three min utes 3 Stop the engine 4 Clean the area around the drain plug 5 Place a drain pan under the crankcase 6 Remove the drain plug Allow the oil to dr...

Page 93: ...good condition 12 Install the new filter and rotate it clockwise by hand until the filter gasket contacts the sealing sur face then turn it an additional 1 2 turn 13 Remove the dipstick Add the prope...

Page 94: ...137 for the part numbers of POLARIS products Maintain the oil level at the bottom of the fill plug hole The fill plug is located on the right side of the ATV behind the footwell The drain plug is loca...

Page 95: ...move the drain plug Allow the oil to drain completely 3 Clean and reinstall the drain plug Torque to specification 4 Remove the fill plug Add the proper amount of the recommended oil 5 Reinstall the f...

Page 96: ...Use Definition operation in ADC mode for prolonged periods constant ADC operation on hilly or mountainous terrain ADC is the primary mode of all wheel drive operation Use the recommended fluid Use of...

Page 97: ...3 Reinstall the fill plug Torque to specification Fluid Change 1 Position the vehicle on a level surface Remove the fill plug 2 Place a drain pan under the demand drive unit Remove the drain plug All...

Page 98: ...it Maintain the fluid level between the minimum and maximum marks on the reservoir See page 137 for the part numbers of POLARIS products NOTICE Do not use brake fluid Brake fluid will damage rubber co...

Page 99: ...eder valves 6 Slowly loosen one of the bleeder valve screws turn counter clock wise and allow fluid and trapped air to flow from the fitting Tighten the screw when clean fluid begins to flow Repeat th...

Page 100: ...products The fill plug is located on the rear of the gearcase The drain plug is located on the bottom of the gearcase Maintain the fluid level at the bottom of the fill hole threads Do not overfill Oi...

Page 101: ...3 Remove the drain plug Allow the oil to drain completely 4 Clean and reinstall the drain plug with a new sealing washer Torque to specification 5 Remove the fill plug Add the proper amount of the rec...

Page 102: ...awn back up from the bottle past the pres sure cap and into the radiator Some coolant level drop on new vehicles is normal as the system is purging itself of trapped air Check the coolant level and ma...

Page 103: ...cap under the front storage com partment 1 View the fluid level in the bottle 2 If the level is low remove the front box 3 Remove the bottle cap and add coolant as needed Maintain the coolant level b...

Page 104: ...un 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...

Page 105: ...verfill The following checks 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 ade...

Page 106: ...at 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 1 and rear 2 of the...

Page 107: ...f the seat near the opposite rear corner 4 Pull upward abruptly to disen gage the under seat fasteners 5 Remove the seat Side Panel Footwell Removal 1 Remove the seat before removing a side panel 2 To...

Page 108: ...om mended tire type size and pressure Tire Tread Depth Always replace tires when tread depth is worn to 1 8 3 mm or less Front Wheel Hub Tightening Front wheel bearing tightness and spindle nut retent...

Page 109: ...the vehicle to the ground 6 Torque the wheel nuts to specification WARNING Loose nuts could cause a tire to come off during operation which could result in an accident or overturn Always ensure that a...

Page 110: ...ove the filter 4 Remove the fabric type pre filter from the main filter Wash the pre filter in soapy water then rinse and let dry 5 Reinstall the pre filter over the main filter Install a new main fil...

Page 111: ...ct any short cir cuits that may have caused the blown fuse then replace the fuse Spare fuses are provided in the fuse box 1 Remove the front box 2 Remove the fuse box cover 3 Remove the suspect fuse f...

Page 112: ...n 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 1 Remove the five 5 headlight pod screws 2 Lift the pod cover an...

Page 113: ...r 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 the wall The most intense part of the headlig...

Page 114: ...Remove the five 5 headlight pod screws 2 Lift the pod cover and disconnect the speedometer harnesses from the speedometer 3 Unplug the headlamp from the wiring harness 4 Use a small screwdriver to re...

Page 115: ...re the head lamp Taillight Brakelight Lamp Replacement 1 Open the tailgate 2 Remove the two screws near the tailgate latch 3 Grasp the entire taillight assembly and pull it away from the vehicle 4 Rem...

Page 116: ...warmed up and the vehicle has been driven at higher speeds Immediately check the spark plug for correct color See page 113 CAUTION A hot exhaust system and engine can cause burns Wear protective glov...

Page 117: ...gine and the service The tip should not be flaky and white A white insulator tip indicates overheating caused by use of an improper spark plug or incorrect fuel Wet Fouled Spark Plug The wet fouled in...

Page 118: ...er Make sure the E ring is on the drain plug and reinstall the drain plug NOTICE Serious damage could occur if the air box drain plug is not reinstalled and tightened properly 3 Remove the spark plugs...

Page 119: ...n from the exhaust pipe muffler 1 Remove the arrester clean out plug from the bottom of the muffler 2 Place the transmission in PARK 3 Start the engine 4 Quickly squeeze and release the throttle lever...

Page 120: ...peeds 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 respons...

Page 121: ...ue to the system s dependence on engine speed For example when operating at a ground speed of 3 MPH 5 km h in low range the engine speed would be around 3000 RPM This is well above the engagement spee...

Page 122: ...ain plug Allow the water to drain completely Rein stall 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 th...

Page 123: ...of the battery could result in electrolyte leakage which would shorten the life of the battery considerably Always keep battery terminals and connections free of corrosion If cleaning is necessary re...

Page 124: ...ease see your POLARIS dealer to purchase a 30 AH battery Before installing the 30 AH battery remove the plastic spacer at the bot tom of the battery compartment Save the spacer for future use 1 Ensure...

Page 125: ...needed to maintain a full charge Tip Power plug leads may need to be bent down so that the battery cover can be installed POLARIS recommends maintaining battery charge by using a POLARIS Battery Tende...

Page 126: ...you must use a voltmeter or multimeter to measure DC voltage WARNING An overheated battery may explode causing severe injury or death Always watch charging times carefully Stop charging if the batter...

Page 127: ...ps specified on top of battery 100 12 8 13 0 volts None check at 3 mos from date of manufacture None required 75 100 12 5 12 8 volts May need slight charge if no charge given check in 3 months 3 6 hou...

Page 128: ...2 3 mm should be visible between the throttle arm stop pin and the throttle arm If adjustment is needed 1 Locate the throttle cable adjuster Squeeze the end of the rubber boot and slide it back far e...

Page 129: ...ase see your POLARIS dealer for service 7 With the engine running turn the handlebars fully to the left and right Tap the throttle lever at each turn verifying that idle RPM returns to the recommended...

Page 130: ...or death Follow the adjustment procedures exactly or see your POLARIS dealer for service 1 Remove the upper headlight pod 2 Loosen the four handlebar bolts 3 Adjust the handlebar to the desired height...

Page 131: ...n adjustable Front and Rear Springs The front and rear shock absorber springs are adjusted by rotating the adjuster either clockwise or counter clockwise to increase or decrease spring tension Accesso...

Page 132: ...e the frame of the ATV to the transporting unit securely with suitable straps or rope Do not attach tie straps to the front A arm bolt pockets 7 Remove the key to prevent loss during transporting Acce...

Page 133: ...to contact the vehicle The best and safest way to clean your POLARIS vehicle is with a gar den hose and a pail of mild soap and water 1 Use a professional type washing cloth cleaning the upper body f...

Page 134: ...washing Allow the engine to run for a while to evaporate any water that may have entered the engine or exhaust system Polishing the Vehicle POLARIS recommends the use of common household aerosol furn...

Page 135: ...beginning on page 81 Demand drive unit front gearcase ADC fluid ADC models change every two years Rear gearcase if equipped Transmission Brake fluid change every two years and any time the fluid look...

Page 136: ...il 5 If POLARIS fuel system additive is not used the fuel tank fuel lines and injectors should be completely drained of gasoline Air Filter Air Box 1 Inspect and clean or replace the pre cleaner and a...

Page 137: ...ift the transmission to low range and carefully use fast aggressive throttle application to engage clutch WARNING Excessive throttle may cause loss of control and vehicle overturn Climbing over large...

Page 138: ...k plug s Inspect plugs and replace if neces sary No spark to spark plug Inspect plugs verify stop switch is on Water or fuel in crankcase Immediately see your POLARIS dealer Low battery voltage Rechar...

Page 139: ...inked or plugged fuel tank vent line Inspect and replace Incorrect fuel Replace with recommended fuel Clogged air filter Inspect and clean or replace Reverse speed limiter malfunction See your dealer...

Page 140: ...oose ignition connections Check all connections and tighten Low battery voltage Recharge the battery to 12 8 VDC Incorrect fuel Replace with fresh recommended fuel Clogged air filter Inspect and clean...

Page 141: ...ml 2872276 Premium ATV Angle Drive Fluid 2 5 gal 9 5 l 2870465 Pump for Gallon 3 8 l Jug Coolant 2871323 60 40 Coolant gal 3 8 l 2871534 60 40 Coolant qt 95 l Grease Specialized Lubricants 2871312 Gr...

Page 142: ...1500 lbs 680 kg on level ground Unbraked Trailer Towing Capacity 1995 lbs 905 kg Overall Length 93 25 in 237 cm Overall Width 47 6 in 121 cm Overall Height 49 5 in 125 7 cm Wheelbase 57 in 145 cm Gro...

Page 143: ...ntrol Hydraulic Disc All Wheel Brake Auxiliary Foot Activated Hydraulic Disc Rear Wheel Brake Parking Hydraulic lock all wheel Headlight 1 Single Beam on Headlight Pod 50 watt 2 Single Beam on Bumper...

Page 144: ...500 lbs 680 kg on level ground Unbraked Trailer Towing Capacity 1995 lbs 905 kg Overall Length 93 25 in 237 cm Overall Width 47 6 in 121 cm Overall Height 49 5 in 125 7 cm Wheelbase 57 in 145 cm Groun...

Page 145: ...ontrol Hydraulic Disc All Wheel Brake Auxiliary Foot Activated Hydraulic Disc Rear Wheel Brake Parking Hydraulic lock all wheel Headlight 1 Single Beam on Headlight Pod 50 watt 2 Single Beam on Bumper...

Page 146: ...h a POLARIS dealer REGISTRATION At the time of sale the Warranty Registration Form must be completed by your dealer and submitted to POLARIS within ten days Upon receipt of this registration POLARIS w...

Page 147: ...parts exposed to friction surfaces stresses environmental conditions and or contamination for which they were not designed or not intended including but not limited to the following items Warranty app...

Page 148: ...clusive option repair or replacement of any defective materials or components or products THE REMEDIES SET FORTH IN THIS WARRANTY ARE THE ONLY REMEDIES AVAILABLE TO ANY PERSON FOR BREACH OF THIS WARRA...

Page 149: ...hey will contact the appropriate person at POLARIS This warranty gives you specific legal rights and you may also have other rights which vary from state to state If any of the above terms are void be...

Page 150: ...any authorized POLARIS dealer who sells the same line as your vehicle Outside the Country where your vehicle was purchased If you are traveling temporarily outside the country where your vehicle was...

Page 151: ...u receive safety information and notices regarding your vehicle Notice If your vehicle is registered outside of the country where it was purchased and you have not followed the procedure set out above...

Page 152: ...components of systems whose only purpose is to control emissions Repairing or replacing other components not covered by this war ranty is the responsibility of the vehicle owner This emissions limited...

Page 153: ...by a defect in material or workman ship This limited warranty does not cover damage due to accidents abuse or improper handling maintenance or use This limited warranty also does not cover any engine...

Page 154: ...section of your manual to your dealer each time your vehicle is serviced This will provide you and future owners with an accurate log of maintenance and ser vices performed DATE MILES KM OR HOURS TECH...

Page 155: ...151 MAINTENANCE LOG DATE MILES KM OR HOURS TECHNICIAN SERVICE PERFORMED COMMENTS...

Page 156: ...g System 98 100 Crankcase Emission Control 80 D Demand Drive Fluid 92 93 Diagnostic Codes 55 Disengaging Active Descent Control 40 Display Units Standard Metric 48 Drive Belt Wear Burn 133 Drivetrain...

Page 157: ...Adjustment 109 High Range Use 118 Hub Tightening 104 I Idle RPM Adjustment 124 Immersion Maintenance 114 Indicator Lamps 45 Instrument Cluster 44 53 K Key Switch 29 K Turn 70 71 L Lights 108 111 Head...

Page 158: ...ck 127 Starting the Engine 61 Steering Assembly 102 Storage 129 132 Storage Tips 131 132 Switches 28 29 4X4 Switch 29 Engine Stop Switch 28 Headlight Switch 29 Main Key Switch 29 Mode Reverse Override...

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