Polaris Sportsman XP 1000 S 2022 Owner'S Manual Download Page 4 | Manualshive

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Lightly® is a registered trademark of the United States Department of
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Unless noted, trademarks are the property of Polaris Industries Inc.

Copyright 2021 Polaris Industries Inc. All information contained 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 accepted for omissions or inaccuracies. Any reprinting or
reuse of the depictions and/or procedures contained within, whether whole or
in part, is expressly prohibited.

The original instructions for this vehicle are in English. Other languages are
provided as translations of the original instructions.

Printed in U.S.A.

9940177 Rev 01

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Summary of Contents for Sportsman XP 1000 S 2022

Page 1: ...ead this manual 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 Sport...

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

Page 3: ...2022 Owner s Manual Sportsman XP 1000 S...

Page 4: ...registered trademark of HWA Fong Rubber USA Inc DBA Duro Tire Wheel Corp AUTOLITE is a registered trademark of BMO HARRIS BANK N A Tread Lightly is a registered trademark of the United States Departme...

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

Page 6: ...4 WELCOME...

Page 7: ...tion 7 Safety 13 Features and Controls 31 Operation 65 Winch Guide 87 Emission Control Systems 97 Maintenance 99 Specifications 151 POLARIS Products 155 Troubleshooting 157 Warranty 167 Maintenance Lo...

Page 8: ...6...

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

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

Page 11: ...tal factors such as ambient noise or temperature RADIO COMPLIANCE STATEMENTS USA RADIO COMPLIANCE This vehicle contains the following radio equipment or components that contain radio equipment COMPONE...

Page 12: ...r s receiver s that comply with Innovation Science and Economic Development Canada s license exempt RSS s Operation is subject to the following two conditions 1 This device may not cause interference...

Page 13: ...and key number in the spaces provided Remove the spare key and store it in a safe place An ignition key can be duplicated only by ordering a POLARIS key blank using your key number and mating it with...

Page 14: ...12...

Page 15: ...rs This training is included in the purchase price of your ATV You were also provided with printed materials that explain safe operating procedures You should review this information on a regular basi...

Page 16: ...ch has granted approval The approval number and serial number will also be displayed on the label EYE PROTECTION Do not depend on eyeglasses or sunglasses for eye protection Whenever riding this POLAR...

Page 17: ...fferent situations and on different types of terrain Beginning and inexperienced operators should complete the recommended safety training before operating this vehicle Never permit a guest to operate...

Page 18: ...spection and maintenance procedures and schedules described in this owner s manual HANDLING GASOLINE Gasoline is highly flammable and explosive under certain conditions Always exercise extreme caution...

Page 19: ...TING ON PAVEMENT This vehicle s tires are designed for off road use only not for use on pavement Operating this vehicle on paved surfaces including sidewalks paths parking lots and driveways may adver...

Page 20: ...rson s feet are not firmly planted on the footrests they could come into contact with the wheels or other moving parts and lead to accident or injury Always keep both hands on the handlebars and both...

Page 21: ...tion for details DESCENDING HILLS IMPROPERLY Improperly descending a hill could cause loss of control or rollover Always follow proper procedures for traveling down hills as described in this owner s...

Page 22: ...ill side of the vehicle or on the left if the vehicle is pointing straight uphill Have a passenger dismount first then the operator may dismount Turn the ATV around and remount following the procedure...

Page 23: ...urn Do not operate on excessively rough slippery or loose terrain until you ve learned and practiced the skills necessary to control the vehicle on such terrain Always use extra caution on rough slipp...

Page 24: ...ollow proper operating procedures as outlined in this manual See the New Operator Driving Procedures section for details Before shifting into reverse gear always check for obstacles or people behind t...

Page 25: ...DAMAGED VEHICLE CAUTION Operating a damaged vehicle can result in an accident After any rollover or other accident have a qualified service dealer inspect the entire machine for possible damage includ...

Page 26: ...you and your cargo together with any other vehicles in your party Always check with local authorities and residents to confirm ice conditions and thickness over your entire route Vehicle operators ass...

Page 27: ...cated above the hitch ball receiver and the trailer hitch During operation of the ATV the exhaust will produce hot exhaust gas that should not be inhaled and that may elevate the surface temperature o...

Page 28: ...mowers blades tires sprayers or large racks may change the handling characteristics of the vehicle Use only POLARIS approved accessories and familiarize yourself with their function and effect on the...

Page 29: ...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 q Age Warning t General Warning...

Page 30: ...amage DISCRETIONARY WARNING WARNING Never operate this ATV on HILLS steeper than 25 degrees To prevent overturn on hilly terrain use throttle and brakes gradually and shift weight uphill REVERSE opera...

Page 31: ...oads a collision can occur with another vehicle with a passenger passengers affect balance and steering and increase risk of losing control ALWAYS use proper riding techniques to avoid vehicle overtur...

Page 32: ...are above 250 lbs 114 kg and or front cargo loads are above 100 lbs 46 kg CLUTCH COVER WARNING WARNING Moving parts hazard under belt clutch guard To prevent serious injury do not operate vehicle with...

Page 33: ...ngine Stop Switch e Mode Reverse Override Switch r Headlight Switch t Throttle Lever y Driveline Switch u Drive Mode Switch if equipped i Auxiliary Switch if equipped o Thumb Warmer Switch if equipped...

Page 34: ...rn the key to the OFF position to stop the engine Electrical circuits are off RUN Turn the key the RUN position to activate electrical components Electrical circuits are on Electrical equipment can be...

Page 35: ...TCH WARNING Pressing the override button while the throttle is open can cause loss of control which may result in serious injury or death Always release the throttle before pressing the override butto...

Page 36: ...ottle problems arise Failure to check or maintain proper operation of the throttle system can result in an accident if the throttle lever sticks during operation Always check the lever for free moveme...

Page 37: ...control setting Operating in rough terrain or over obstacles Loading the vehicle onto a trailer Towing heavy loads Driving frequently at low RPM or at ground speeds below 7 MPH 11 km h PERFORMANCE MO...

Page 38: ...your POLARIS dealer or other qualified service facility for proper diagnosis and repairs NOTICE The hand brake lever controls both the front and rear brakes Always squeeze the hand brake whenever usin...

Page 39: ...Do not overfill Use DOT 4 brake fluid only 5 Reinstall the cover Torque screws to specification TORQUE Brake Fluid Reservoir Cover Screws 7 in lbs 1 N m IMPORTANT Always properly break in the brake s...

Page 40: ...G Never back down a hill Applying the auxiliary brake when backing down a hill may cause rear tipover which could result in serious injury or death Use caution when applying the auxiliary brake Do not...

Page 41: ...age For brake system break in information see the Operation chapter BRAKE FLUID LEVEL Check the brake fluid level frequently for the auxiliary brake system The reservoir is located under the front sto...

Page 42: ...d or unleaded gasoline with a minimum pump octane number of 87 R M 2 octane Do not use fuel with ethanol content greater than 10 percent such as E 85 fuel ELECTRONIC POWER STEERING EPS Electronic powe...

Page 43: ...FRONT RACK If your model is equipped with front compartment storage unlock both latches on each side and remove the cover to gain access 41 FEATURES AND CONTROLS...

Page 44: ...e lever to the desired gear NOTE Shifting gears with the engine speed above idle or while the vehicle is moving could cause transmission damage Whenever the ATV is left unattended always place the tra...

Page 45: ...t rest AWD MODE To engage AWD mode push the momentary switch to the right AWD will engage when engine speed slows to below 3100 RPM The gauge will display AWD There is no limit to the length of time t...

Page 46: ...scending or descending a hill ENGAGING ACTIVE DESCENT CONTROL The ADC system will automatically engage when all four of the following conditions occur The 4X4 switch must be in the ADC 4X4 position Ve...

Page 47: ...pper right corner of the gauge at start up If your model is equipped with a no button gauge use the MODE button on the left hand control to navigate the display menu NOTICE The use of a high pressure...

Page 48: ...area displays engine RPM ground speed or coolant temperature r Fuel Gauge The segments of the fuel gauge show the level of fuel in the fuel tank When the last segment clears a low fuel warning is act...

Page 49: ...e key is left in the ON position for at least 5 minutes Cycle the key off and back on to restore function and turn off lamp Engine Hot This lamp illuminates to indicate an overheated engine If the ind...

Page 50: ...high beam Performance Limited On models equipped with a low speed limiter indicator light will remain on when low speed limiter is active Lamp illuminates when Geofencing or max speed is enabled Lamp...

Page 51: ...formation displayed in Area 1 q DISPLAY AREA 1 FUNCTION Speed The vehicle s speed will be displayed in mph or km h Engine Temperature The vehicle s current engine temperature will be displayed RPM The...

Page 52: ...e will be displayed Trip 1 The vehicle Trip 1 mileage will be displayed Trip 2 The vehicle Trip 2 mileage will be displayed RPM The vehicle RPM will be displayed Voltage The vehicle s current battery...

Page 53: ...nt or stored Units Distance Select MPH or KPH Units Temp Select between F and C Clock Select between 12H or 24H and set time Backlight Color Select between Blue or Red Backlight Level Set backlight br...

Page 54: ...s before showing first menu item 2 Select Diagnostic Codes from the Options Menu by pressing the MODE button Toggle the Up Down Buttons to cycle through Code s NOTICE This option will only be availabl...

Page 55: ...nd the item listed in the chart Shorted Load The wires leading to the item listed in the chart are shorted together or the item has shorted internally Short to Battery The wire leading from the item l...

Page 56: ...Circuit Open Grounded 652 5 Driver Circuit Short to B 652 3 Driver Circuit Grounded 652 4 Ignition Coil Primary Driver 1 MAG Driver Circuit Short to B 1268 3 Ignition Coil Primary Driver 2 PTO Driver...

Page 57: ...Driver Circuit Short to B 520208 3 Driver Circuit Grounded 520208 4 All Wheel Drive Control Driver Circuit Open Grounded 520207 5 Driver Circuit Short to B 520207 3 Driver Circuit Grounded 520207 4 Sy...

Page 58: ...ve Normal Operational Range Most Severe Level 84 0 Data Erratic Intermittent Or Incorrect 84 2 Abnormal Rate Of Change 84 10 Received Network Data In Error 84 19 System Power Data Valid But Above Norm...

Page 59: ...eering Torque Full Failure Condition Exists 520224 31 EPAS Inverter Temperature Data Valid But Above Normal Operational Range Most Severe Level 520225 0 Data Valid But Above Normal Operating Range Mod...

Page 60: ...rst menu item 2 Select Units Distance from the Options Menu by pressing the MODE button Reference the image shown above q Press the MODE button w Toggle the Up Down Buttons to change the units MPH or...

Page 61: ...the image shown above q Press the MODE button w Toggle the Up Down Buttons to change the units F or C e With the correct unit displayed Press the mode button which will set the unit and return to the...

Page 62: ...units Cycles Hours t With the correct unit displayed Press the mode button which will set the unit y Toggle the Up Down Buttons to change the units Cycles 10s of Minutes u With the correct unit displa...

Page 63: ...image shown above q Press the MODE button w Toggle the Up Down Buttons to change the units Blue or Red e With the correct unit displayed Press the mode button which will set the unit and return to the...

Page 64: ...own above q Press the MODE button w Toggle the Up Down Buttons to change the units Increase or De crease Level e With the correct unit displayed Press the mode button which will set the unit and retur...

Page 65: ...to change the units 0 5 10 95 100 e With the correct unit displayed press the MODE button which will set the unit and return you to the Options Menu NOTICE To reset service hours after they have count...

Page 66: ...ocedure to pair your phone with the vehicle s digital gauge NOTICE Bluetooth functionality is compatible with both iOS and Android phones For iOS phones you must go to the Settings option and enable n...

Page 67: ...f gasoline No single action 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 fo...

Page 68: ...ter the first 25 hours of operation and every 100 hours thereafter BRAKE SYSTEM BREAK IN Apply only moderate braking force for the first 50 stops Aggressive or overly forceful braking when the brake s...

Page 69: ...operating at slower speeds during the break in period as recommended Pull only light loads Avoid aggressive acceleration and high speed operation during the break in period If a belt fails always cle...

Page 70: ...ect lubricate if necessary Steering Ensure free operation Tires Inspect condition and pressure page 118 Wheels fasteners Inspect ensure fastener tightness Frame nuts bolts fasteners Inspect ensure tig...

Page 71: ...ment or on any public street road or highway including dirt and gravel roads 7 Use caution and drive at reduced speeds in conditions of reduced visibility such as fog rain and darkness Clean headlight...

Page 72: ...LARIS dealer a local riding club or local officials Help keep our trails open for recreational vehicle use As an off road enthusiast you represent the sport and can set a good example or a poor exampl...

Page 73: ...temperature decreases DRIVING PROCEDURES NEW OPERATOR DRIVING PROCEDURES 1 Wear protective riding gear See the Safe Riding Gear section 2 Perform the pre ride inspection 3 Place the transmission in PA...

Page 74: ...feet on the footrests 5 Lean your upper body to the inside of the turn while supporting your weight on the outer footrest This technique alters the balance of traction between the rear wheels allowin...

Page 75: ...ese precautions 1 Do not operate on excessively rough slippery or loose terrain 2 Slow down when entering slippery areas 3 Engage 4X4 before wheels begin to lose traction NOTICE Severe damage to drive...

Page 76: ...refully before ascending any hill 5 Never climb hills with excessively slippery or loose surfaces 6 Keep both feet on the footrests 7 Shift body weight uphill 8 Proceed at a steady rate of speed and t...

Page 77: ...ith the transmission in forward gear Do not descend a hill with the transmission in neutral 5 Slow down Never travel down a hill at high speed 6 Drive straight downhill Avoid traveling down a hill at...

Page 78: ...tely necessary If crossing a sidehill is unavoidable follow these precautions 1 Slow down 2 Avoid crossing the side of a steep hill 3 Lean into the hill transferring your upper body weight toward the...

Page 79: ...side of the vehicle or on the left if the vehicle is pointing straight uphill 5 Staying uphill of the vehicle turn the handlebars full left 6 While holding the brake lever release the parking brake lo...

Page 80: ...section of this manual and take the vehicle in for service at the first opportunity Your ATV can operate through water with a maximum recommended depth equal to the bottom of the footrests Follow the...

Page 81: ...ert for hazards such as logs rocks and low hanging branches 3 Travel slowly and use extra caution when operating on unfamiliar terrain Not all obstacles are immediately visible 4 Never attempt to oper...

Page 82: ...the throttle suddenly 7 Do not use the override switch unless additional wheel speed is required for vehicle movement Use the override with caution as rearward vehicle speed is greatly increased Do no...

Page 83: ...es evenly and firmly Practice starting and stopping using the brakes until you re familiar with the controls PARKING THE VEHICLE 1 Stop the vehicle on a level surface When parking inside a garage or o...

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

Page 85: ...s raises the center of gravity of the vehicle and creates a less stable operating condition SECURE ALL LOADS BEFORE OPERATING Unsecured loads can create unstable operating conditions which could resul...

Page 86: ...or towing heavy cargo to extend belt life 8 Always operate the vehicle with extreme caution whenever hauling or towing loads Balance handling and control may be affected TOWING LOADS Always attach a...

Page 87: ...IMUM TOWING CAPACITIES Do not exceed maximum towing capacities Avoid towing on inclines XP 1000 S Maximum Towed Load Level Ground 1750 lbs 794 kg Maximum Vertical Hitch Weight 175 lbs 79 kg 85 OPERATI...

Page 88: ...86...

Page 89: ...e winch cable fairlead and hook when operating winch 6 Never attempt to jerk a load attached to the winch with a moving vehicle See the Shock Loading section on page 95 7 Always keep the area around t...

Page 90: ...ds or if the winch stalls during operation stop winching and permit the winch to cool down for 10 minutes before using it again 16 Never touch push pull or straddle the winch cable while winching a lo...

Page 91: ...ing Always remember that your winch is very powerful There are simply some situations that you and your winch will not be able to deal with Do not be afraid to ask others to help when this happens 1 A...

Page 92: ...be released if the winch cable breaks This can result in SEVERE INJURY or DEATH See the Shock Loading section on page 95 Never hook the winch cable back onto itself This will damage the winch cable a...

Page 93: ...Release the winch clutch and pull out the winch cable 7 Pulling out as much cable as possible maximizes the winch s pulling capacity Always be sure that at least five 5 full turns of winch cable are w...

Page 94: ...hen winching a vehicle free a Release the winch clutch and spool out the necessary length of winch cable b Align the winch cable as close as possible to the winching vehicle s centerline c Attach the...

Page 95: ...if winching at an angle it may be necessary to re distribute the winch cable across the winch drum You will need an assistant to perform this task a Release the clutch on the winch b Feed out the winc...

Page 96: ...this cable has already been permanently and severely damaged Promptly discontinue use of a winch cable in this condition A kinked winch cable made of wire rope that has been straightened out is shown...

Page 97: ...tra load on the winch winch cable and generates excessive heat from the motor This is a form of shock loading 3 Never tow a vehicle or other object with your winch Towing an object with a winch produc...

Page 98: ...your safety always replace POLARIS winch parts including the cable with genuine POLARIS replacement parts available at your authorized POLARIS dealer or other qualified person 5 Some winch models use...

Page 99: ...s engine is equipped with a closed crankcase system Blow by gases are forced back to the combustion chamber by the intake system All exhaust gases exit through the exhaust system EXHAUST EMISSION CONT...

Page 100: ...98...

Page 101: ...tified in this owner s manual Careful periodic maintenance will help keep your vehicle in safe reliable condition Inspect clean lubricate adjust and replace parts as necessary When inspection reveals...

Page 102: ...BOL DESCRIPTION XU Perform these procedures more often for vehicles subjected to severe use D Have an authorized Polaris dealer or other qualified person perform these services WARNING Improperly perf...

Page 103: ...y 100 160 Inspect periodically Battery 20 H Monthly 200 320 Check terminals clean test Fuel System 20 H Monthly Turn key on to pressurize fuel pump check lines fittings for leaks and abrasion XU Engin...

Page 104: ...2 M 600 1000 Change fluid XU Transmission oil 100 H 12 M 600 1000 Change fluid D Fuel System 100 H 12 M 600 1000 Cycle key to pressurize fuel pump check for leaks at fill cap fuel lines rail and fuel...

Page 105: ...ITEM MAINTENANCE INTERVAL WHICHEVER COMES FIRST REMARKS HOUR S CALENDAR MILES KM D Toe Adjustment Inspect periodically adjust as needed Headlight Aim Adjust as needed 103 MAINTENANCE...

Page 106: ...104 MAINTENANCE...

Page 107: ...Engine Oil PS 4 5W 50 4 Cycle Oil 2 qt 1 9 l 12 ft lbs 16 N m page 106 Transmission Oil AGL Gearcase Lubricant Transmission Fluid 37 oz 1100 ml 14 ft lbs 19 N m 14 ft lbs 19 N m page 110 Demand Drive...

Page 108: ...ngine oil will cause accelerated wear and may result in engine seizure accident and injury Always perform the maintenance procedures as outlined in the Periodic Maintenance Chart OIL RECOMMENDATIONS A...

Page 109: ...ick and fill tube from the left 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 recomm...

Page 110: ...Allow it to warm up at idle for two to three minutes 3 Stop the engine 4 Clean the area around the drain plug 5 Place a drain pan under the crankcase 6 Remove the drain plug Allow the oil to drain com...

Page 111: ...ure the o ring is in good condition 13 Install the new filter and rotate it clockwise by hand until the filter gasket contacts the sealing surface then turn it an additional 1 2 turn 14 Remove the dip...

Page 112: ...e bottom rear side of the gearcase OIL CHECK 1 Remove the fill plug 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...

Page 113: ...4 Reinstall the fill plug Torque to specification TORQUE Fill Plug 14 ft lbs 19 N m 5 Check for leaks 6 Reinstall the footwell 7 Dispose of used oil properly 111 MAINTENANCE...

Page 114: ...ied 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 p...

Page 115: ...iodic Maintenance Chart See page 155 for the part numbers of POLARIS 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...

Page 116: ...l the fill plug Torque to specification TORQUE Fill Plug 12 in lbs 16 7 Check for leaks 8 Dispose of used oil properly POWER STEERING UNIT IF EQUIPPED If your model is equipped with power steering fre...

Page 117: ...ris Products section for the part numbers RECOVERY BOTTLE COOLANT The recovery bottle fluid level can be viewed from inside the front right wheel well Access the recovery bottle cap under the front bo...

Page 118: ...cap 3 Using a funnel slowly add coolant through the radiator filler neck 4 Reinstall the pressure cap Use of a non standard pressure cap will not allow the recovery system to function properly Your P...

Page 119: ...n if brakes are used heavily under normal operation 1 Always keep brake fluid at an adequate level See the Master Cylinder Brake Fluid section for details 2 Check the brake system for fluid leaks 3 Ch...

Page 120: ...al 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 Al...

Page 121: ...g 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 the...

Page 122: ...in a straight ahead position 3 Tie a length of string between two stands Position the stands so that the string is flush with the side of the rear tire If available you may use a long straight edge i...

Page 123: ...y need replacement Locate and correct any short circuits that may have caused the blown fuse then replace the fuse Spare fuses are provided in the fuse box 1 Access the fuses under the front box 2 Rem...

Page 124: ...ow lamps to cool before servicing 1 Remove the four 4 headlight pod screws Pull the pod cover forward 2 Unplug the headlamp from the wiring harness Be sure to pull on the connector not on the wiring 3...

Page 125: ...ly upward or downward by rotating the adjustment screw located on either side of the vehicle HEADLIGHT HOUSING REPLACEMENT 1 Remove the four 4 headlight pod screws 2 Pull the pod cover forward 3 Unplu...

Page 126: ...the back of the light assembly 3 Remove the 3 fasteners securing the light assembly and then remove the assembly 4 Install the new light assembly then re affix and tighten the 3 fasteners 5 Reinstall...

Page 127: ...gher speeds Immediately check the spark plug for correct color CAUTION A hot exhaust system and engine can cause burns Wear protective gloves when removing a spark plug for inspection Allow engine to...

Page 128: ...air box and replace the filter with a new filter If equipped remove the air box drain plug q to drain water Reinstall the drain plug Make sure the E ring is on the drain plug and reinstall the drain p...

Page 129: ...sult from contact with the exhaust components Allow components to cool sufficiently before proceeding Never operate without the spark arrester Periodically clean the spark arrester to remove accumulat...

Page 130: ...g is securely in place during operation The basic operation of the POLARIS PVTsystem is dependent on engine speed and vehicle torque requirements As engine speed increases the force exerted on the mov...

Page 131: ...hen water is accidently ingested into the PVT system Use the following instructions to dry it out before operating 1 Position the vehicle on a level surface 2 Remove the drain plug Allow the water to...

Page 132: ...afely support the rear of the vehicle 3 Remove the left rear wheel from the vehicle 4 Remove the 4 bolts q retaining the lower LH frame support w and remove from the frame 5 Remove the rear skid plate...

Page 133: ...that it can be installed in the same direction 10 Insert the provided clutch tool between the slides and rotate the tool to spread the sheaves Spanner Wrench Spreader PN 2877408 NOTICE Ensure the too...

Page 134: ...nner Wrench Spreader PN 2877408 NOTICE Ensure the tool is square with the moveable sheave surface of the driven clutch 2 Release the sheaves and rotate the driven clutch counter clockwise to ensure th...

Page 135: ...50 N m 6 Install the left rear wheel and torque wheel nuts to specification TORQUE Wheel Lug Nuts Aluminum 75 ft lbs 102 N m Wheel Lug Nuts Steel 45 ft lbs 61 N m 7 Reinstall the seat and remaining bo...

Page 136: ...connections free of corrosion If cleaning is necessary remove corrosion with a stiff wire brush Wash with a solution of one tablespoon baking soda and one cup water Rinse well with tap water and dry...

Page 137: ...s with dielectric grease or petroleum jelly 4 Secure the battery hold down strap 5 Connect and tighten the red positive cable first 6 Connect and tighten the black negative cable last 7 Verify that ca...

Page 138: ...ger on the ground or on a suitable elevated surface Never place the charger on the vehicle or let it hang from the battery charge port while plugged in BATTERY CHARGING The following battery charging...

Page 139: ...for recharging When using a constant current charger use the following guidelines via the table below BATTERY CHARGING SEALED BATTERY Always verify battery condition before and 1 2 hours after the en...

Page 140: ...tery life All Polaris ORV models include either a Conventional battery or a Low Maintenance battery CONVENTIONAL BATTERY The battery is NOTactivated when packaged Distilled water and electrolyte added...

Page 141: ...r put the sealing cap back onto the battery The gas pressure can cause the battery to rupture Let the battery sit for 30 minutes after you add the initial electrolyte Once absorbed fill the battery wi...

Page 142: ...e battery to activate the battery Keep the electrolyte container in place for 20 minutes or longer until the container is completely empty If necessary gently tap the container to empty it Once the ba...

Page 143: ...30 of the battery s full potential Nominal voltage is 12 6 to 12 8 Volts when fully charged If the voltage falls below 12 5V charge it immediately or the battery service life and vehicle performance m...

Page 144: ...the life of the battery If you do not drive the vehicle for more than TWO weeks maintain the battery with the BatteryMINDer 2012 AGM 2 AMP PN 2830438 charger If you plan to store the vehicle for ONE...

Page 145: ...cm Rear Suspension 15 56 in 39 5 cm Follow these guidelines if you make adjustments to this suspension Always return the suspension to the factory setting after the load is removed from the vehicle T...

Page 146: ...hock damage will occur FACTORY CLICKER SETTINGS Front Suspension 8 Clicks from Full Stiff Rear Suspension 8 Clicks From Full Stiff CROSSOVER RING ADJUSTMENT To adjust the preload do the following 1 El...

Page 147: ...es 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 Be sure the handlebars do not contact...

Page 148: ...nents Labels and decals If an informational or graphic label becomes illegible or comes off contact your POLARIS dealer to purchase a replacement Replacement safety labels are provided by POLARIS at n...

Page 149: ...2 Add POLARIS Carbon Clean Fuel Treatment or POLARIS Fuel Stabilizer or equivalent fuel treatments or stabilizers Follow the instructions on the container for the recommended amount Carbon Clean remo...

Page 150: ...from the spark plug cavities into the hole at the front of the cylinder head and appear to be an oil leak 3 Reinstall the spark plugs Torque to specification 4 Apply dielectric grease to the inside of...

Page 151: ...in PARK 3 Lock the parking brake 4 Secure the fuel cap oil cap and seats 5 Always tie the frame of the ATV to the transporting unit securely with suitable straps or rope Do not attach tie straps to t...

Page 152: ...150...

Page 153: ...age Box Capacity 200 lbs 91 kg Rear Rack Capacity 300 lbs 136 kg Receiver Hitch Tongue Capacity 175 lbs 79 kg Rear rack load and tongue weight not to exceed 300 lbs 136 kg Hitch Towing Rating 1750 lbs...

Page 154: ...sive rate with 14 in 35 5 cm travel Transmission H L N R P Gear Reduction Low 5 034 1 Gear Reduction Reverse 4 508 1 Gear Reduction High 2 367 1 Drive Ratio Front 3 818 1 Drive Ratio Rear 3 7 1 Tires...

Page 155: ...TCHING CLUTCH SETTINGS Altitude Shift Weight Drive Spring Driven Spring Helix Meters Feet 0 1800 0 6000 23 64 1323575 42 140 Purple 7043805 Black 140 240 7045111 62SR BA45 3236443 1800 6000 24 60 5632...

Page 156: ...154...

Page 157: ...2878069 Pump for Gallon Jug 1 2870465 Demand Drive 1 qt 0 95 L 12 2877922 2 5 gal 9 5 L 2 2877923 Antifreeze Coolant 1 qt 0 95 L 12 2880514 1 gal 3 8 L 6 2880513 Grease Gun Kit Premium All Season 1 2...

Page 158: ...PRODUCT SIZE QUANTITY QUANTITY PART NUMBER 2 5 gal 9 5 L 2 2872280 DOT 4 Brake Fluid 1 2872189 Loctite 565 Thread Sealant 1 2871956 POLARIS Battery Tender Charger 1 2859044 156 POLARIS PRODUCTS...

Page 159: ...NG Excessive throttle may cause loss of control and vehicle rollover Climbing over large objects from a stopped position Shift the transmission to low range and carefully use fast brief aggressive thr...

Page 160: ...ecessary No spark to spark plug Inspect plug and replace if necessary Water or fuel in crankcase Your authorized dealer can assist Low battery voltage Recharge the battery to 12 8 VDC Mechanical failu...

Page 161: ...Water present in fuel Replace with new fuel Low battery voltage Recharge battery to 12 8 VDC Incorrect fuel Replace with recommended fuel Clogged air filter Inspect and clean or replace Clogged intak...

Page 162: ...e with fresh recommended fuel Clogged air filter Inspect and clean or replace Clogged intake pre filter Inspect and clean with soapy water or replace Other mechanical failure Your authorized dealer ca...

Page 163: ...shorted to a wire at battery voltage DIAGNOSTIC CODES COMPONENT CONDITION SPN FMI Throttle Position Sensor Voltage Too High 51 3 Voltage Too Low 51 4 Engine Temperature Sensor Voltage Too High 110 3 V...

Page 164: ...to B 1268 3 Ignition Coil Primary Driver 2 PTO Driver Circuit Short to B 1269 3 Fuel Pump Driver Circuit Driver Circuit Open Grounded 1347 5 Driver Circuit Short to B 1347 3 Driver Circuit Grounded 1...

Page 165: ...to B 520207 3 Driver Circuit Grounded 520207 4 System Power Voltage Too High 168 3 Voltage Too Low 168 4 Throttle Safety Signal Voltage Too High 520194 3 Voltage Too Low 520194 4 Signal Out of Range 5...

Page 166: ...Normal Or Shorted To High Source 168 3 Voltage Below Normal Or Shorted To Low Source 168 4 Engine Speed Data Valid But Above Normal Operational Range Most Severe Level 190 0 Data Erratic Intermittent...

Page 167: ...25 16 EPAS Communications Receive Data Error Data Erratic Intermittent Or Incorrect 520226 2 Condition Exists 520226 31 Position Encoder Error Root Cause Not Known 520228 11 Bad Intelligent Device Or...

Page 168: ...166...

Page 169: ...uch 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...

Page 170: ...ingestion contamination improper maintenance modified components use of aftermarket or unapproved components accessories or attachments use of unapproved software or calibration unauthorized repairs o...

Page 171: ...Y POLARIS SHALL HAVE NO LIABILITY TO ANY PERSON FOR INCIDENTAL CONSEQUENTIAL OR SPECIAL DAMAGES OF ANY DESCRIPTION WHETHER ARISING OUT OF EXPRESS OR IMPLIED WARRANTY OR ANY OTHER CONTRACT NEGLIGENCE O...

Page 172: ...tion from the country of the selling dealer s authorized location as proof of residence Upon residence verification the servicing dealer will be authorized to perform the warranty repair IF YOU MOVE I...

Page 173: ...ot followed the procedure set above your product will no longer be eligible for warranty or service bulletin coverage of any kind other than safety bulletins Products registered to government official...

Page 174: ...date of purchase whichever comes first This EPA emissions warranty period is extended for at least as long as the standard factory warranty that Polaris provides on the vehicle as a whole The EPA emis...

Page 175: ...OF ANY DESCRIPTION WHETHER ARISING OUT OF EXPRESS OR IMPLIED WARRANTY OR ANY OTHER CONTRACT NEGLIGENCE OR OTHER TORT OR OTHERWISE THIS EXCLUSION OF CONSEQUENTIAL INCIDENTAL AND SPECIAL DAMAGES IS INDE...

Page 176: ...manufacturer reduces the effectiveness of the vehicle s emission controls Tampering with emission controls is prohibited by federal law CALIFORNIA RESIDENTS Certain POLARIS Off Road Vehicles are avail...

Page 177: ...MAINTENANCE LOG MAINTENANCE LOG Use the following chart to record periodic maintenance DATE MILES KM OR HOURS TECHNICIAN SERVICE PERFORMED COMMENTS 175 MAINTENANCE LOG...

Page 178: ...DATE MILES KM OR HOURS TECHNICIAN SERVICE PERFORMED COMMENTS 176 MAINTENANCE LOG...

Page 179: ...Crossover Ring Adjustment 144 D Descending Hills Improperly 19 Diagnostic Display Code Definitions 53 161 Disengaging Active Descent Control 44 Drive Belt Installation 132 Removal 130 Drive Belt Wear...

Page 180: ...ms 25 How To Obtain Warranty Service 170 I Improper Cargo Loading 24 Improper Hill Climbing 19 Improper Tire Maintenance 22 Inspect and Lubricate 148 Instrument Cluster 45 Back Light Color 61 Back Lig...

Page 181: ...shing the Vehicle 146 Poor Visibility 24 Power Steering Unit Cleaning 114 Pre Ride Checklist 68 Protective Apparel 17 PVT Break in Clutches Belt 66 PVT System 128 R Rack Box Warning 28 Radiator Coolan...

Page 182: ...r Hitch Warning 25 Transmission Oil 110 Transporting the ATV 149 Turning Around on a Hill K Turn 77 Turning Improperly 18 U Unauthorized Use of the Vehicle 25 V Vehicle Break in Period 65 Vehicle Iden...

Page 183: ......

Page 184: ...ith a passenger passengers affect balance and steering and can increase risk of losing control Always use proper riding techniques to avoid vehicle overturns on hills and rough terrain and in turns av...

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