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PMS 419 Failure to heed the warnings and safety precautions contained in this manual can result in severe injury or death. Read this manual carefully. POLARIS ACE™ POLARIS ACE™ 570 Owner's Manual for Maintenance and Safety 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. WARNING The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects or other reproductive harm. For videos and more information about a safe riding experience with your Polaris vehicle, scan this QR code with your smartphone. WELCOME Thank you for purchasing a POLARIS vehicle, and welcome to our world-wide family of POLARIS enthusiasts. Be sure to visit us online at www.polaris.com for the latest news, new product introductions, upcoming events, career opportunities and more. Here at POLARIS we proudly produce an exciting line of utility and recreational products. • • • • • • Snowmobiles All-terrain vehicles (ATVs) Low emission vehicles (LEVs) RANGER® utility vehicles BRUTUS® work vehicles SLINGSHOT® three wheel motorcycles • • • • • • RZR® sport vehicles GEM® electric vehicles VICTORY® motorcycles INDIAN® motorcycles POLARIS POWER® generators POLARIS DEFENSE® combat vehicles We believe POLARIS sets a standard of excellence for all utility and recreational vehicles manufactured in the world today. Many years of experience have gone into the engineering, design, and development of your POLARIS vehicle. For safe and enjoyable operation of your vehicle, be sure to follow the instructions and recommendations in this owner’s manual. Review the safety DVD that came with your vehicle. POLARIS also recommends that all drivers take the ROHVA safety e-course and a ROHVA hands-on safety training course. Visit www.rohva.org or call 866-267-2751. 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) Technician. Your POLARIS dealer knows your vehicle best and is interested in your total satisfaction. Your POLARIS dealership can provide for all of your service needs during, and after, the warranty period. 1 POLARIS® and ACE™ are trademarks of POLARIS Industries Inc. Copyright 2015 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. 2016 POLARIS ACE/ACE 570 Owner’s Manual P/N 9926060 2 TABLE OF CONTENTS Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Features and Controls . . . . . . . . . . . . . . . . . . . 24 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 Winch Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . 69 Emission Control Systems . . . . . . . . . . . . . . . 80 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . 81 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . 132 POLARIS Products. . . . . . . . . . . . . . . . . . . . . 134 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . 135 Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139 Maintenance Log . . . . . . . . . . . . . . . . . . . . . . 146 Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147 3 INTRODUCTION This POLARIS vehicle is an off-road vehicle. Familiarize yourself with all laws and regulations concerning the operation of this vehicle in your area. The following signal words and symbols appear throughout this manual and on your vehicle. Your safety is involved when these words and symbols are used. Become familiar with their meanings before reading the manual. The safety alert symbol indicates a potential personal injury hazard. DANGER A DANGER indicates a hazardous situation 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 indicates a hazardous situation that, if not avoided, could result in minor or moderate injury. NOTICE A NOTICE indicates a situation that could result in property damage. The Prohibition Safety Sign indicates an action NOT to take in order to avoid a hazard. The Mandatory Action Sign indicates an action that NEEDS to be taken to avoid a hazard. 4 INTRODUCTION WARNING Failure to heed the warnings and safety precautions contained in this manual can result in severe injury or death. Your POLARIS vehicle is not a toy and can be hazardous to operate. This vehicle handles differently than cars, trucks or other off-road vehicles. A collision or rollover can occur quickly, even during routine maneuvers like turning, or driving on hills or over obstacles, if you fail to take proper precautions. • Read this owner’s manual and review the safety DVD that came with your vehicle. A free extra copy of the DVD can be obtained by contacting your local POLARIS dealer. Understand all safety warnings, precautions and operating procedures before operating the vehicle. Keep this manual with the vehicle. • Never operate this vehicle without proper instruction. Take an authorized training course. Visit www.rohva.org or call 866-267-2751. • 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 parts inside the vehicle at all times. • Always wear a helmet, eye protection, gloves, long-sleeve shirt, long pants and over-the-ankle boots. • Never use this vehicle with drugs or alcohol, as these conditions impair judgment and reduce operator reaction time. • Complete the New Operator Driving Procedures outlined on pages 56-57. Never allow a guest to operate this vehicle until the guest has completed the New Operator Driving Procedures. • Never permit a guest to operate this vehicle unless the guest has reviewed the owner’s manual and all safety labels and has completed a safety training course. European Vibration and Noise The driver-perceived noise and hand/arm and whole body vibration levels of this machinery is measured per prEN 15997. The operating conditions of the machinery during testing: The vehicles were in like-new condition. The environment was controlled as indicated by the test procedure(s). The uncertainty of vibration exposure measurement is dependent on many factors, including: • Instrument and calibration uncertainty • Variations in the machine such as wear of components • Variation of machine operators such as experience or physique • Ability of the worker to reproduce typical work during measurements • Environmental factors such as ambient noise or temperature 5 INTRODUCTION Vehicle Identification Numbers Record your vehicle's identification numbers 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 one of your existing keys. The ignition switch must be replaced if all keys are lost. Engine Serial Number 570 VIN (Right Front Frame) 325 Key Number #### Vehicle Model Number: ___________________________________________________ Vehicle Identification Number (VIN): _________________________________________ Engine Serial Number: ___________________________________________________ Key Number ____________________________________________________________ 6 SAFETY Safety Training Safety training is a top priority for POLARIS. POLARIS strongly encourages you and any family members who will be riding this vehicle to take a training course. ROHVA (Recreational Off-Highway Vehicle Association) provides both an online safety e-course and a hands-on safety course. Visit www.rohva.org or call 866-267-2751. Your POLARIS vehicle is considered an off-road vehicle. Familiarize yourself with all laws and regulations concerning the operation of this vehicle in your area. We strongly advise you to strictly follow the recommended maintenance program outlined in your owner's manual. This preventive maintenance program is designed to ensure that all critical components on your vehicle are thoroughly inspected at specific intervals. For more information about recreational off-road vehicle safety in the United States, visit www.rohva.org, call 866-267-2751 or call POLARIS at 800-342-3764. 7 SAFETY Safe Riding Gear Always wear helmet, eye protection, gloves, long-sleeve shirt, long pants, over-the-ankle boots and seat belt at all times. Protective gear reduces the chance of injury. Helmet Wearing a helmet can prevent a severe head injury. Whenever riding this POLARIS vehicle, always wear a helmet that meets or exceeds established safety standards. Approved helmets in the USA and Canada bear a U.S. Department of Transportation (DOT) label. E4 Approved helmets in Europe, Asia and Oceania 051039 bear the ECE 22.05 label. The ECE mark consists 0006.31 of a circle surrounding the letter E, followed by the distinguishing number of the country which has granted approval. The approval number and serial number will also be displayed on the label. Helmet Eye Protection Long Sleeves Gloves Long Pants Over-the-Ankle Boots 8 SAFETY Safe Riding Gear 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 Protective Equipment (PPE) bearing markings such as VESC 8, V-8, Z87.1, or CE. Make sure protective eye wear is kept clean. Gloves Wear gloves for comfort and for protection from sun, cold weather and other elements. Boots Wear sturdy over-the-ankle boots for support and protection. Never ride a POLARIS vehicle with bare feet or sandals. Clothing Wear long sleeves and long pants to protect arms and legs. Rider Comfort Under certain operating conditions, heat generated by the engine and exhaust system can elevate temperatures in the rider cab area. The condition occurs most frequently when a vehicle is being operated in high ambient temperatures at low speeds and/or high load conditions for an extended period of time. The use of certain windshield, roof and/or cab systems may contribute to this condition by restricting airflow. Any discomfort due to heat buildup in this area can be minimized by wearing proper riding apparel and by varying speeds to increase airflow. 9 SAFETY Safety Labels and Locations Warning labels have been placed on the vehicle for your protection. Read and follow the instructions of the labels on the vehicle carefully. If any of the labels depicted in this manual differ from the labels on your vehicle, always read and follow the instructions of the labels on the vehicle. If an informational or graphic label becomes illegible or comes off, contact your POLARIS dealer to purchase a replacement. Replacement safety labels are provided by POLARIS at no charge. The part number is printed on the label. General Warning 10 SAFETY Safety Labels and Locations General Warning WARNING Require Proper Use of Your Vehicle Do your part to prevent injuries: • Do not allow careless or reckless driving. • Make sure operators are 16 or older with a valid driver’s license. • Do not let people drive after using alcohol or drugs. • Do not allow operation on public roads (unless designated for off-highway vehicle access) - collisions with cars and trucks can occur. • Do not exceed seating capacity: 1 occupant. Improper vehicle use can result in SEVERE INJURY or DEATH Be Prepared • Fasten seat belt. • Wear an approved helmet and protective gear. • ALWAYS use vehicle cab nets and/or doors. • Driver must be able to sit with back against seat, feet flat on the floor, and hands on steering wheel. Stay completely inside the vehicle. Drive Responsibly Avoid loss of control and rollovers: • Avoid abrupt maneuvers, sideways sliding, skidding or fishtailing, and never do donuts. • Slow down before entering a turn. • Avoid hard acceleration when turning, even from a stop. • Plan for hills, rough terrain, ruts and other changes in traction and terrain. • Avoid paved surfaces. • Avoid sidehilling (riding across slopes). Rollovers have caused severe injuries and death, even on flat, open areas. Be Sure to Pay Attention and Plan Ahead If you think or feel the vehicle may tip or roll, reduce your risk of injury: • Keep a firm grip on the steering wheel and brace yourself. • Do not put any part of your body outside of the vehicle for any reason. LOCATE AND READ OWNER’S MANUAL. FOLLOW ALL INSTRUCTIONS AND WARNINGS. ALWAYS REVIEW SAFETY VIDEO AND TAKE ROHVA TRAINING (rohva.org). 7180534 11 SAFETY Safety Labels and Locations Load/Passenger/Tire Pressure Warning WARNING • Never carry passengers in cargo box. • Passengers can be thrown off. This can cause serious injury or death. Load/Passenger/Tire Pressure Warning WARNING IMPROPER TIRE PRESSURE OR OVERLOADING CAN CAUSE LOSS OF CONTROL RESULTING IN SERIOUS INJURY OR DEATH. • Reduce speed and allow greater distance for braking when carrying cargo. • Overloading or carrying tall, off-center, or unsecured loads will increase your risk of losing control. Loads should be centered and carried as low as possible in box. • For stability on rough or hilly terrain, reduce speed and cargo. ACE MAXIMUM CARGO BOX LOAD 240 lbs. (108 kg) TIRE PRESSURE IN PSI (KPa) FRONT 7 (48) REAR 7 (48) MAXIMUM WEIGHT CAPACITY INCLUDES WEIGHT OF OPERATOR, CARGO AND ACCESSORIES 575 lbs. (260 kg) Read Operation and Maintenance Manual for more detailed loading information. 7180636 Maximum Payload Warning WARNING Never exceed 43 MPH (70 km/h) if total payload exceeds 335 lbs. (152 kg). 7181835 12 SAFETY Safety Labels and Locations PVT System Warning WARNING Improper service or maintenance of this PVT system can result in vehicle damage, SEVERE INJURY or DEATH. Always look for and remove debris inside and around clutch and vent system when replacing belt. Read owner's manual or see authorized Polaris dealer. 7177469 PVT System Warning Hitch Capacity Label TRAILER MAX WEIGHT: 1500 LBS. (682 KG) ON LEVEL GROUND 850 LBS. (386 KG) UP TO 15 DEGREES HITCH MAX. VERTICAL WEIGHT: 150 LBS. (68 KG) 7170509 13 SAFETY Safety Warnings WARNING Failure to operate this vehicle properly can result in a collision, loss of control, accident or rollover, which may result in serious injury or death. Heed all safety warnings outlined in this section of the owner’s manual and in the safety DVD provided with your vehicle. See the OPERATION section of the owner’s manual for proper operating procedures. Operating Without Instruction Operating this vehicle without proper instruction increases the risk of an accident. The operator must understand how to operate the vehicle properly in different situations and on different types of terrain. Complete the New Operator Driving Procedures outlined on pages 56-57. All operators must read and understand the owner's manual and all warning and instruction labels before operating the vehicle. Never allow a guest to operate this vehicle until the guest has completed the New Operator Driving Procedures outlined on pages 56-57. Age Restrictions This vehicle is an ADULT VEHICLE ONLY. Operation is prohibited for anyone under 16 years of age or anyone without a valid driver’s license. The operator must be tall enough to sit with back against the seat, both feet flat on the floor and both hands on the steering wheel. Using Alcohol or Drugs Operating this vehicle after consuming alcohol or drugs could adversely affect operator judgment, reaction time, balance and perception. Never consume alcohol or drugs before or while operating this vehicle. 14 SAFETY Safety Warnings Failure to Inspect Before Operating Failure to inspect and verify that the vehicle is in safe operating condition before operating increases the risk of an accident. Always perform the pre-ride inspection before each use of your vehicle to make sure it's in safe operating condition. See page 51. Always follow the inspection and maintenance procedures and schedules described in this owner’s manual. See page 81. 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. Always wear a helmet, eye protection, gloves, long-sleeve shirt, long pants and over-the-ankle boots. Seat Belts Riding in this vehicle without wearing the seat belt increases the risk of serious injury in the event of rollover, loss of control, other accident or sudden stop. Seat belts may reduce the severity of injury in these circumstances. The operator MUST wear the seat belt at all times. Cab Nets Riding in this vehicle without using the cab nets (or doors, if equipped) increases the risk of serious injury or death in the event of an accident or rollover. Always use the cab nets (or doors) while riding in this vehicle. Always keep hands and feet inside the vehicle at all times. 15 SAFETY Safety Warnings Carrying a Passenger This POLARIS vehicle is a single-rider vehicle. Carrying a passenger greatly reduces the operator's ability to control the vehicle, which may result in an accident or rollover. Carrying a passenger in the cargo box could result in a fall from the vehicle or contact with moving components. Never carry a passenger on this vehicle. Operating With a Load on the Vehicle The weight of both cargo and operator impacts vehicle operation and stability. For your safety and the safety of others, carefully consider how your vehicle is loaded and how to safely operate the vehicle. Follow the instructions in this manual for loading, tire pressure, gear selection and speed. • Do not exceed vehicle weight capacities. The vehicle’s maximum weight capacity is listed in the specifications section of this manual and on a label on the vehicle. When determining the weight you are adding to the vehicle, include the weight of the operator, accessories, loads in the rack or box and the load on the trailer tongue. The combined weight of these items must not exceed the maximum weight capacity. • The recommended tire pressures are listed in the specifications section of this manual and on a label on the vehicle. Always follow these guidelines: Under ANY of these conditions: Do ALL of these steps: Operator and/or cargo exceeds half the maximum weight capacity 1. Slow down. 2. Verify tire pressure. 3. Use extra caution when operating. Operating in rough terrain Operating over obstacles Climbing an incline Towing 16 SAFETY Safety Warnings Improper Tire Maintenance Operating this vehicle with improper tires or with improper or uneven tire pressure could cause loss of control or accident. Always use the size and type of tires specified for your vehicle. Always maintain proper tire pressure as described in the owner's manual and on safety labels. Operating 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 adversely affect the handling of the vehicle and may increase the risk of loss of control and accident or rollover. Avoid operating the vehicle on pavement. If it's unavoidable, travel slowly, travel short distances and avoid sudden turns or stops. Operating on Public Roads Operating this vehicle on public streets, roads or highways could result in a collision with another vehicle. Never operate this vehicle on any public street, road or highway, including dirt and gravel roads (unless designated for off-highway use). Operating at Excessive Speeds Operating this vehicle at excessive speeds increases the operator's risk of losing control. Always operate at a speed that's appropriate for the terrain, the visibility and operating conditions and your skills and experience. 17 SAFETY Safety Warnings Turning Improperly Turning improperly could cause loss of traction, loss of control, accident or rollover. Always follow proper procedures for turning as described in this owner’s manual. Avoid sharp turns. Never turn while applying heavy throttle. Never make abrupt steering maneuvers. Practice turning at slow speeds before attempting to turn at faster speeds. Jumps and Stunts Exhibition driving increases the risk of an accident or rollover. DO NOT do power slides, “donuts”, jumps or other driving stunts. Avoid exhibition driving. Improper Hill Climbing Improper hill climbing could cause loss of control or rollover. Use extreme caution when operating on hills. Always follow proper procedures for hill climbing as described in this owner's manual. See page 60. 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 manual. See page 62. 18 SAFETY Safety Warnings Crossing Hillsides Driving on a sidehill is not recommended. Improper procedure could cause loss of control or rollover. Avoid crossing the side of any hill unless absolutely necessary. If crossing a hillside is unavoidable, always follow proper procedures as described in this owner's manual. See page 61. Stalling While Climbing a Hill Stalling or rolling backwards while climbing a hill could cause a rollover. Maintain a steady speed when climbing a hill. If you lose all forward speed: Apply the brakes gradually until the vehicle is fully stopped. Place the transmission in reverse and slowly allow the vehicle to roll straight downhill while applying light brake pressure to control speed. Operating in Unfamiliar Terrain Failure to use extra caution when operating on unfamiliar terrain could result in an accident or rollover. Unfamiliar terrain may contain hidden rocks, bumps, or holes that could cause loss of control or rollover. Travel slowly and use extra caution when operating on unfamiliar terrain. Always be alert to changing terrain conditions. 19 SAFETY Safety Warnings Operating Improperly in Reverse Improperly operating in reverse could result in a collision with an obstacle or person. Always follow proper operating procedures as outlined in this manual. See page 65. Before shifting into reverse gear, always check for obstacles or people behind the vehicle. When it's safe to proceed, back slowly. Improper Tire Maintenance Operating this vehicle with improper tires or with improper or uneven tire pressure could cause loss of control, accident or rollover. Always use the size and type of tires specified for your vehicle. Always maintain proper tire pressure as described in this owner's manual and on safety labels. Skidding or Sliding Failure to use extra caution when operating on excessively rough, slippery or loose terrain could cause loss of traction, loss of control, accident or rollover. Do not operate on excessively slippery surfaces. Always slow down and use additional caution when operating on slippery surfaces. Skidding or sliding due to loss of traction can cause loss of control or rollover (if tires regain traction unexpectedly). Always follow proper procedures for operating on slippery surfaces as described in this owner's manual. See page 59. 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 large rocks and fallen trees. Always follow the proper procedures outlined in this manual when operating over obstacles. See page 64. 20 SAFETY Safety Warnings Operating Through Water Operating through deep or fast-flowing water can cause loss of traction, loss of control, rollover or accident. Never operate in fast-flowing water or in water that exceeds the floor level of the vehicle. Always follow proper procedures for operating in water as described in this owner’s manual. See page 63. Wet brakes may have reduced stopping ability. After leaving water, test the brakes. Apply them lightly several times while driving slowly. The friction will help dry out the pads. Operating on Frozen Bodies of Water Severe injury or death can result if the vehicle and/or the operator fall through the ice. Never operate the vehicle on a frozen body of water unless you have first verified that the ice is sufficiently thick to support the weight and moving force of the vehicle, 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 assume all risk associated with ice conditions on frozen bodies of water. Operating a Damaged Vehicle 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, including (but not limited to) seat belts, rollover protection devices, brakes, throttle and steering systems. 21 SAFETY Safety Warnings Improper Cargo Loading Overloading the vehicle or carrying/towing cargo improperly may cause changes in stability and handling, which could cause loss of control or an accident. • Always follow the instructions in this owner’s manual for carrying cargo. See page 66. • Never exceed the stated load capacity for this vehicle. See page 12. • Cargo should be properly distributed and securely attached. See page 66. • Reduce speed when carrying cargo or pulling a trailer. Allow a greater distance for braking. Poor Visibility Operating this vehicle in darkness or inclement weather could result in a collision or accident, especially if operating on a road or street. This vehicle is not equipped with highway-approved lights. Operate this vehicle off-road only. 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. Refueling Gasoline is highly flammable and explosive under certain conditions. • Always exercise extreme caution whenever handling gasoline. • Always turn off the engine when refueling. • Always refuel outdoors or in a well ventilated area free of any source of flame or sparks. • Always use an approved gasoline container to store fuel and remove the container from the vehicle before filling to avoid fuel ignition due to electrical static discharge. • Do not smoke or allow open flames or sparks in or near the area where refueling is performed or where gasoline is stored. • Do not overfill the tank. Do not fill the tank neck. • If gasoline spills on your skin or clothing, immediately wash it off with soap and water and change clothing. 22 SAFETY Safety Warnings 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. Operate this vehicle only outdoors or in well-ventilated areas. Hot Exhaust Systems Exhaust system components are very hot during and after use of the vehicle. Hot components can cause burns and fire. Do not touch hot exhaust system components. Always keep combustible materials away from the exhaust system. Use caution when traveling through tall grass, especially dry grass, to avoid debris build-up around the exhaust system. 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. Always remove the ignition key when the vehicle is not in use. Equipment Modifications Your POLARIS vehicle is designed to provide safe operation when used as directed. Modifications to your vehicle may negatively impact vehicle stability. Failure of critical machine components may result from operation with any modifications, especially those that increase speed or power. This vehicle may become less stable at speeds higher than those for which it is designed. Loss of control may occur at higher speeds. Do not install any non-POLARIS-approved accessory or modify the vehicle for the purpose of increasing speed or power. Any modifications or installation of non-POLARIS-approved accessories could create a substantial safety hazard and increase the risk of bodily injury. The POLARIS limited warranty on your POLARIS vehicle will be terminated if any non-POLARIS approved equipment and/or modifications have been added to the vehicle that increase speed or power. The addition of certain accessories, including (but not limited to) 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 vehicle. FOR MORE INFORMATION ABOUT SAFETY call POLARIS at 1-800-342-3764. 23 FEATURES AND CONTROLS Component Locations Single-Rider Seat ROPS Frame Steering Wheel Hip Bars Cargo Box Front Box Cover Taillights Headlights Engine Intake Pre-Filter Cab Nets Brush Guard Radiator Brake Pedal 24 Throttle Pedal Fuel Cap Shifter FEATURES AND CONTROLS Trailer Receiver Hitch Bracket This vehicle is equipped with a receiver hitch bracket for a trailer hitch. Trailer towing equipment is not supplied with this vehicle. To avoid injury and property damage, always heed the warnings and towing capacities outlined on pages 66-68. Service Access Panels Receiver Hitch Access serviceable engine components through the engine access panel behind the seat. Remove the seat and release the access panel latches to remove the access panel. Remove rear access panel to access the air box and spark plug. The rear access panel is located in the bed of the cargo box. Pull the rear edge of the access panel upward to remove it. Rear Access Panel Radiator Access/Bumper Removal The front bumper can be removed to clean debris from the radiator. 1. Remove the four (4) torx screws and six (6) plastic rivets. 2. Lift the front bumper to remove it from the vehicle. Screws Rivets 25 FEATURES AND CONTROLS Steering Wheel The steering wheel can be tilted upward or downward for rider preference. Lift and hold the steering wheel adjustment lever while moving the steering wheel upward or downward. Release the lever when the steering wheel is at the desired position. Always make sure the steering wheel position does not impede proper operation of the brake pedal, throttle pedal and all other controls. Front Box Cover Remove the front box cover and access panel to access the radiator cap, coolant overflow bottle and brake master cylinder reservoir. 1. Turn the box cover fasteners 1/4 turn. 2. Lift the rear edge of the box cover. 3. Using the pliers provided in the tool kit, remove the two (2) push darts from the access panel. Remove the panel. 26 Adjustment Lever Cover Fasteners Access Panel FEATURES AND CONTROLS Cab Nets Riding in this vehicle Cab Net Latches without using the cab nets (or doors, if equipped) increases the risk of serious injury or death in the event of an accident or rollover. Cab nets (or doors) must be used at all times. Make sure all latches on both sides of the vehicle are secure before operating the vehicle. Always inspect cab nets and latches for tightness, wear and damage before each use of the vehicle. Use the strap adjusters to tighten any loose straps. Promptly replace worn or damaged cab nets and latches with new cab nets and latches. Your POLARIS dealer can assist. Extreme Use Battery An optional extreme use battery may be available for your model. If the performance of the factory-installed battery is inadequate due to operation in extreme cold or due to extended use of multiple electrical accessories, your POLARIS dealer can assist. Your dealer can provide any installation procedures that may differ for an extreme use battery. Electronic Power Steering (EPS) 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 page 37 for EPS Warning Indicator information. 27 FEATURES AND CONTROLS Fuel Cap The fuel tank filler cap is located on the right side of the vehicle near the seat. When refueling, always use either leaded 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. Fuel Cap Seat Seat Adjustments Always make sure the seat position allows for proper access and operation of the brake pedal, throttle pedal and all other controls. The seat release lever is located at the left side of the seat. Push the release lever downward and slide the seat forward or rearward to the desired position. Release the lever. The seat will lock into the new position. Seat Removal 1. Push the seat release lever downward and slide the seat forward until it slides off the frame. 2. Lift the seat away from the vehicle. 3. Reverse the procedure to reinstall the seat. Seat Release Lever 28 FEATURES AND CONTROLS Seat Belt This POLARIS vehicle is equipped with three-point lap and diagonal seat belts. Always secure the seat belt before riding. To wear the seat belt properly, follow this procedure: 1. Pull the seat belt latch downward and across your chest toward the buckle at the inner edge of the seat. The belt should fit snugly across your hips and diagonally across your chest. Make sure the belt is not twisted. 2. Push the latch plate into the buckle until it clicks. 3. Release the strap, it will self-tighten. 4. Press the red release latch on the buckle to release the seat belt. Seat Belt Inspection Inspect all seat belts for proper operation before each use of the vehicle. 1. Push the latch plate into the buckle until it clicks. The latch plate must slide smoothly into the buckle. A click indicates that it's securely latched. 2. Push the red release latch in the middle of the buckle to make sure it releases freely. 3. Pull each seat belt completely out and inspect the full length for any damage, including cuts, wear, fraying or stiffness. If any damage is found, or if the seat belt does not operate properly, have the seat belt system checked and/or replaced by an authorized POLARIS dealer. 4. To clean dirt or debris from the seat belts, sponge the straps with mild soap and water. Do not use bleach, dye or household detergents.Use a garden hose to flush out the retractor and latch housing regularly. Latch Housing Retractor Housing 29 FEATURES AND CONTROLS Switches Instrument Cluster AWD Switch 12V Accessory Outlet Ignition Switch/Light Switch 30 FEATURES AND CONTROLS Switches Ignition Switch/Light Switch Use the ignition switch to start the engine OFF and to turn the lights on or off. The key can be removed from the switch when it is in the OFF position. OFF Turn the key to the OFF position to stop the engine. Electrical circuits are off. LIGHTS ON The lights are on. Electrical circuits are on. Electrical equipment can be used. LIGHTS OFF The lights are off. Electrical circuits are on. Electrical equipment can be used. START Turn the key to the START position to engage the electric starter. See page 54 for starting procedures. START All Wheel Drive (AWD) Switch (if equipped) The AWD Switch has two positions: • All Wheel Drive (AWD) • Two Wheel Drive (2WD). Press the top of the rocker switch to engage All Wheel Drive. Press the bottom of the switch to operate in two wheel drive. See page 35 for AWD operating instructions. AWD 2WD Auxiliary Outlet The vehicle is equipped with a 12-volt accessory outlet on the dash. Use the outlet to power an auxiliary light or other optional accessories or lights. For service, the dash outlet connection is under the dash. 31 FEATURES AND CONTROLS Gear Selector To change gears, stop the vehicle, and with the engine idling, move the lever to the desired gear. Do not attempt to shift gears with engine speed above idle or while the vehicle is moving. P: Park R: Reverse N: Neutral L: Low Gear H: High Gear Gear Selector NOTICE: Do not attempt to shift the transmission while the vehicle is moving or damage to the transmission could result. Always shift when the vehicle is stationary and the engine is at idle. Using Low Range Always shift into low gear for any of the following conditions. • Operating in rough terrain or over obstacles • Loading the vehicle onto a trailer • Towing heavy loads 32 FEATURES AND CONTROLS Brake Pedal Depress the brake pedal to slow or stop the vehicle. Apply the brakes while starting the engine. Throttle Pedal Push the pedal down to increase engine speed. Spring pressure returns the pedal to the rest position when released. Always check that the throttle pedal returns normally before starting the engine. Make sure there's adequate throttle pedal freeplay. See page 109. This vehicle is equipped with a throttle release switch, which is designed to reduce the risk of a frozen or stuck throttle. If the throttle cable should stick in an open position when the operator releases the throttle pedal, engine speed will be limited, and power to the rear wheels will be reduced. Brake Pedal Throttle Pedal 33 FEATURES AND CONTROLS Rollover Protective Structure (ROPS) The Rollover Protective Structure (ROPS) on this vehicle meets OSHA 1928.53 rollover performance requirements. Always have your authorized POLARIS dealer thoroughly inspect the ROPS if it ever becomes damaged in any way. No device can assure occupant protection in the event of a rollover. When used with seat belts and cab nets, the ROPS helps prevent occupants from being ejected from the vehicle. Always follow all safe operating practices outlined in this manual to avoid vehicle rollover. ROPS Label (on ROPS behind rear cab) WARNING! Vehicle rollover could cause severe injury or death. Always avoid operating in a manner that could result in vehicle rollover. 34 FEATURES AND CONTROLS All Wheel Drive (AWD) System The All Wheel Drive system is controlled by the AWD switch. When the switch is on 2WD (2X4), AWD the vehicle is in two-wheel drive at all times. When the switch is on AWD (4x4), the vehicle is in all wheel drive and the 4X4 indicator in the instrument cluster will be on. When in AWD, the demand drive unit will 2WD automatically engage any time the rear wheels lose traction. When the rear wheels regain traction, the demand drive unit will automatically disengage. There is no limit to the length of time the vehicle may remain in AWD. Engaging AWD The AWD switch may be turned on or off while the vehicle is moving. Initially, the vehicle's electronic system will not enable the AWD until the engine RPM is below 3100. Once enabled, the AWD remains enabled until the AWD 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. Engage the AWD switch before getting into conditions where front wheel drive may be needed. If the rear wheels are spinning, release the throttle before switching to AWD. NOTICE: Switching to AWD while the rear wheels are spinning or slipping may cause severe drive shaft and gearcase damage. Always switch to AWD while the rear wheels have traction or are at rest. 35 FEATURES AND CONTROLS Instrument Cluster High water pressure may damage components. Wash the vehicle by hand or with a garden hose using mild soap. Do not use alcohol to clean the instrument cluster. Do not allow insect sprays to contact the lens. Speedometer Indicator Lamps Speedometer The speedometer displays vehicle speed in either miles per hour (MPH) or kilometers per hour (km/h). See page 40. Mode Button Use the MODE button to toggle through mode options. See page 40 for operation of the modes. 36 Rider Information Center MODE Button FEATURES AND CONTROLS Instrument Cluster Indicator Lamps Lamp Indicates Condition When standard mode is selected, speed displays in Vehicle miles per hour. Speed When metric mode is selected, speed displays in kilometers per hour. Over This lamp illuminates to indicate an overheated Temperature engine. If the indicator flashes, the overheating condition remains, and the system will automatically reduce engine power. Neutral This lamp illuminates when the transmission is in neutral and the ignition key is in the ON position. High Beam (if This lamp illuminates when the headlamp switch is equipped) set to high beam. Helmet/Seat This lamp flashes for several seconds when the key is Belt turned to the ON position. The lamp is a reminder to wear helmet and seat belt before operating. Check Engine This indicator appears if an EFI-related fault occurs. Do not operate the vehicle if this warning appears. Serious engine damage could result. Your authorized POLARIS dealer can assist. EPS Warning This indicator illuminates when the key is turned to (if equipped) the ON position and goes off when the engine is started. If the light remains on after starting the engine, the EPS system is inoperative. Your authorized POLARIS dealer can assist. 37 FEATURES AND CONTROLS Instrument Cluster Rider Information Center The rider information center is located in the instrument cluster. All segments will light up for one second at start-up. If the instrument cluster fails to illuminate, a battery over-voltage may have occurred and the instrument cluster may have shut off to protect the electronic speedometer. If this occurs, your POLARIS dealer can provide proper diagnosis. The information center is set to display standard units of measurement and a 12-hour clock at the factory. To change to metric and/or a 24-hour clock, see page 41. 2 E F RPM Trip 1 1 3 km 88:88 8 6 7 mi 4 5 1. Gear Indicator - This indicator displays gear shifter position. H = High Gear L = Low Gear N = Neutral R = Reverse Gear P = Park -- = Gear Signal Error (or shifter between gears) 38 FEATURES AND CONTROLS Instrument Cluster Rider Information Center 2. 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. Tip: If the fuel icon fails to display, an open or short circuit has occurred in the fuel sensor circuit. Your authorized POLARIS dealer can assist. 3. Information Display Area - This area displays odometer, trip meter, engine hour meter and programmable service hour interval. 4. Under / Over Voltage - This warning usually indicates that the vehicle is operating at an RPM too low to keep the battery charged. It may also occur when the engine is at idle and high electrical load (lights, cooling fan, accessories) is applied. Drive at a higher RPM or recharge the battery to clear the warning. 5. Clock - The clock displays time in a 12-hour or 24-hour format. See page 41 for resetting instructions. 6. Service Indicator - A flashing wrench symbol alerts the operator that the preset service interval has been reached. Your POLARIS dealer can provide scheduled maintenance. See page 41 for resetting instructions. 7. 4X4 Indicator - This indicator illuminates when the 4X4 system is engaged (switch is on 4X4). 8. Turf Mode Indicator (if equipped) - This indicator illuminates when the operator unlocks the differential. 39 FEATURES AND CONTROLS Instrument Cluster Rider Information Center Use the MODE button to toggle through the information area options. Display Units (Standard/Metric) The display can be changed to show either standard or metric units of measurement for each of the following settings. MODE Button Tip: To exit the set-up mode, turn the key off. Wait 5 seconds, then turn the key on. The gauge display the mode that was displayed prior to setting the units. Distance Fuel Temperature Time Standard Display Miles U.S. Gallons Fahrenheit 12-Hour Clock Metric Display Kilometers Liters, Imperial Gallons Celsius 24-Hour Clock 1. Turn the key to the OFF position. 2. Press and hold the MODE button while turning the key to the ON position. 3. When the display flashes the distance setting, tap the MODE button to advance to the desired setting. 4. Press and hold the MODE button to save the setting and advance to the next display option. 5. Repeat the procedure to change remaining display settings. 40 FEATURES AND CONTROLS Instrument Cluster Rider Information Center Clock Mode Tip: The clock must be reset any time the battery has been disconnected or discharged. 1. Turn the key to the ON position. Use the MODE button to toggle to the odometer display. 2. Press and hold the MODE button until the hour segment flashes. Release the button. 3. With the segment flashing, tap the MODE button to advance to the desired setting. 4. Press and hold the MODE button until the next segment flashes. 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 the OFF position. Odometer Mode The odometer records and displays the distance traveled by the vehicle. Trip Meter Mode The trip meter records the distance traveled by the vehicle if reset before each trip. To reset, select the trip meter mode. Press and hold the MODE button until the meter resets to zero. In the Rider Information Center, the trip meter display contains a decimal point, but the odometer displays without a decimal point. Hour Meter Mode This mode logs the total hours the engine has been in operation. Engine Temperature Mode This mode displays current temperature of the coolant. Tachometer Mode The engine RPM is displayed digitally. Tip: Small fluctuations in the RPM from day to day may be normal because of changes in humidity, temperature and elevation. 41 FEATURES AND CONTROLS Instrument Cluster Rider Information Center Programmable Service Interval When the hours of engine operation equal the programmed service interval setting, the wrench icon will flash for 5 seconds each time the engine is started. When this feature is enabled, it provides a convenient reminder to perform routine maintenance. The service interval is programmed at 50 hours at the factory. Use the following procedure to change the service interval. 1. Press the MODE button until remaining service hours display. 2. Press and hold the MODE 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. Diagnostic Display Mode The EFI diagnostic display mode is for informational purposes only. Your POLARIS dealer can provide for all major repairs. The diagnostic mode is accessible only when the check engine warning indicator activates after the key has been turned on. Leave the key on if you want to view the active code (failure code). The diagnostic mode becomes inaccessible if the key is turned off and on and the warning indicator is no longer active. This allows the determination of persistent as well as intermittent faults. Inactive codes are stored in the history of the unit. 42 FEATURES AND CONTROLS Instrument Cluster Rider Information Center Engine Error Codes Suspect Parameter Error Code The error screen displays Number (SPN) Number (0-9) only when the CHECK ENGINE light is on or when it goes on and off during one ignition cycle. Error codes are not stored. When the key is turned OFF, the code and message is lost, but will reappear if the fault reoccurs after restarting the engine. Failure Mode Indicator (FMI) If the CHECK ENGINE light illuminates, retrieve the error codes from the display. 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 hold the MODE button to enter the diagnostics code menu. 3. Record the three numbers displayed in the gear position, clock and odometer displays. 4. Press the MODE button to advance to the next error code. 5. Press and hold the MODE button to exit the diagnostics code menu. 6. See pages 44-45 for code definitions and failure descriptions. Your authorized POLARIS dealer can provide code details and diagnosis. 43 FEATURES AND CONTROLS Instrument Cluster Diagnostic Display Code Definitions Open Load: There is a break in the wires that lead to the item listed in the chart (injector, fuel pump, etc.), or the 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 shorted together, or the item has shorted internally. Short-to-Battery: The wire leading from the item listed in the chart to the electronic control unit is shorted to a wire at battery voltage. Diagnostic Codes Component Accelerator Position 2 Throttle Position Sensor 1 Vehicle Speed Sensor Accelerator Position 1 Manifold Absolute Pressure Sensor 44 Condition Data Erratic, Intermittent Or Incorrect Voltage Above Normal, Or Shorted To High Source Voltage Below Normal, Or Shorted To Low Source Data Valid But Above Normal Operational Range - Most Severe Level Data Valid But Below Normal Operational Range - Most Severe Level Data Erratic, Intermittent Or Incorrect Voltage Above Normal, Or Shorted To High Source Voltage Below Normal, Or Shorted To Low Source Abnormal Rate Of Change Out Of Calibration Data Valid But Above Normal Operational Range - Most Severe Level Data Valid But Below Normal Operational Range - Most Severe Level Data Erratic, Intermittent Or Incorrect Voltage Above Normal, Or Shorted To High Source Voltage Below Normal, Or Shorted To Low Source Abnormal Frequency Or Pulse Width Or Period Abnormal Update Rate Abnormal Rate Of Change Bad Intelligent Device Or Component Received Network Data In Error Data Erratic, Intermittent Or Incorrect Voltage Above Normal, Or Shorted To High Source Voltage Below Normal, Or Shorted To Low Source Data Erratic, Intermittent Or Incorrect Voltage Above Normal, Or Shorted To High Source Voltage Below Normal, Or Shorted To Low Source Mechanical System Not Responding Or Out Of Adjustment Abnormal Rate Of Change SPN FMI 29 29 29 51 2 3 4 0 51 1 51 51 51 51 51 84 2 3 4 10 13 0 84 1 84 84 84 84 84 84 84 84 91 91 91 102 102 102 102 102 2 3 4 8 9 10 12 19 2 3 4 2 3 4 7 10 FEATURES AND CONTROLS Instrument Cluster Diagnostic Display Code Definitions Diagnostic Codes Component Condition SPN FMI Intake Air Temperature Sensor Data Erratic, Intermittent Or Incorrect Voltage Above Normal, Or Shorted To High Source Voltage Below Normal, Or Shorted To Low Source Abnormal Rate Of Change Data Valid But Above Normal Operating Range - Least Severe Level Data Valid But Above Normal Operational Range - Most Severe Level Data Erratic, Intermittent Or Incorrect Voltage Above Normal, Or Shorted To High Source Voltage Below Normal, Or Shorted To Low Source Abnormal Rate Of Change Data Valid But Above Normal Operating Range - Least Severe Level Data Valid But Above Normal Operating Range - Moderately Severe Level Data Valid But Below Normal Operating Range - Least Severe Level Data Valid But Above Normal Operational Range - Most Severe Level Data Valid But Below Normal Operational Range - Most Severe Level Voltage Above Normal, Or Shorted To High Source Voltage Below Normal, Or Shorted To Low Source Data Valid But Above Normal Operating Range - Moderately Severe Level Data Valid But Below Normal Operating Range - Moderately Severe Level Data Valid But Above Normal Operational Range - Most Severe Level Data Valid But Below Normal Operational Range - Most Severe Level Data Erratic, Intermittent Or Incorrect Mechanical System Not Responding Or Out Of Adjustment Received Network Data In Error Condition Exists Data Erratic, Intermittent Or Incorrect Voltage Above Normal, Or Shorted To High Source Voltage Below Normal, Or Shorted To Low Source Abnormal Update Rate Bad Intelligent Device Or Component Out Of Calibration Out Of Calibration Data Erratic, Intermittent Or Incorrect Abnormal Frequency Or Pulse Width Or Period Voltage Above Normal, Or Shorted To High Source Voltage Below Normal, Or Shorted To Low Source Current Below Normal Or Open Circuit 105 105 105 105 105 2 3 4 10 15 110 0 110 110 110 110 110 2 3 4 10 15 110 16 110 17 168 0 168 1 168 168 168 3 4 16 168 18 190 0 190 1 190 190 190 190 523 523 523 523 628 628 630 636 636 651 651 651 2 7 19 31 2 3 4 9 12 13 13 2 8 3 4 5 Engine Temperature Sensor System Power Engine Speed Gear Sensor Signal ECU Memory Calibration Crankshaft Position Sensor Injector 1 (Front) (MAG) (SDI Port Injector) 45 FEATURES AND CONTROLS Instrument Cluster Diagnostic Display Code Definitions Diagnostic Codes Component Fan Relay Driver Circuit Ignition Coil Primary Driver 1 (Front) (MAG) Fuel Pump Driver Circuit Oxygen Sensor 1 ECU Output Supply Voltage 1 ECU Output Supply Voltage 2 ECU Output Supply Voltage 3 ETC Accelerator Position Sensor Outputs 1 & 2 Correlation 46 Condition SPN FMI Voltage Above Normal, Or Shorted To High Source Voltage Below Normal, Or Shorted To Low Source Current Below Normal Or Open Circuit Voltage Above Normal, Or Shorted To High Source Voltage Below Normal, Or Shorted To Low Source Current Below Normal Or Open Circuit Voltage Above Normal, Or Shorted To High Source Voltage Below Normal, Or Shorted To Low Source Current Below Normal Or Open Circuit Data Erratic, Intermittent Or Incorrect Voltage Above Normal, Or Shorted To High Source Voltage Below Normal, Or Shorted To Low Source Bad Intelligent Device Or Component Data Valid But Above Normal Operational Range - Most Severe Level Data Valid But Below Normal Operational Range - Most Severe Level Voltage Above Normal, Or Shorted To High Source Voltage Below Normal, Or Shorted To Low Source Data Valid But Above Normal Operating Range - Moderately Severe Level Data Valid But Below Normal Operating Range - Moderately Severe Level Data Valid But Above Normal Operational Range - Most Severe Level Data Valid But Below Normal Operational Range - Most Severe Level Voltage Above Normal, Or Shorted To High Source Voltage Below Normal, Or Shorted To Low Source Data Valid But Above Normal Operating Range - Moderately Severe Level Data Valid But Below Normal Operating Range - Moderately Severe Level Data Valid But Above Normal Operational Range - Most Severe Level Data Valid But Below Normal Operational Range - Most Severe Level Voltage Above Normal, Or Shorted To High Source Voltage Below Normal, Or Shorted To Low Source Data Valid But Above Normal Operating Range - Moderately Severe Level Data Valid But Below Normal Operating Range - Moderately Severe Level Data Erratic, Intermittent Or Incorrect 1071 1071 1071 1268 1268 1268 1347 1347 1347 3056 3056 3056 3056 3597 3 4 5 3 4 5 3 4 5 2 3 4 12 0 3597 1 3597 3597 3597 3 4 16 3597 18 3598 0 3598 1 3598 3598 3598 3 4 16 3598 18 3599 0 3599 1 3599 3599 3599 3 4 16 3599 18 65613 2 FEATURES AND CONTROLS Instrument Cluster Diagnostic Display Code Definitions Diagnostic Codes Component Throttle Position Sensor 2 Active Descent Control System Fuel Correction Front All Wheel Drive Control Circuit Oxygen Sensor Heater 1 Accelerator Position/Brake Position Interaction Throttle Position Sensor (1 or 2 Indeterminable) Throttle Body Control Power Stage Throttle Body Control Return Spring Check Failed Throttle Body Control Adaption Aborted Throttle Body Control Limp Home Position Check Failed Throttle Body Control Mechanical Stop Adaptation Failure Throttle Body Control Repeated Adaptation Failed Throttle Body Control Condition SPN FMI Data Valid But Above Normal Operational Range Most Severe Level Data Valid But Below Normal Operational Range Most Severe Level Data Erratic, Intermittent Or Incorrect Voltage Above Normal, Or Shorted To High Source Voltage Below Normal, Or Shorted To Low Source Abnormal Rate Of Change Out Of Calibration Voltage Above Normal, Or Shorted To High Source 520198 0 520198 1 520198 520198 520198 520198 520198 520203 2 3 4 10 13 3 Voltage Below Normal, Or Shorted To Low Source 520203 4 Current Below Normal Or Open Circuit 520203 5 Data Valid But Above Normal Operating Range Least Severe Level Data Valid But Below Normal Operating Range Least Severe Level Voltage Above Normal, Or Shorted To High Source Voltage Below Normal, Or Shorted To Low Source Current Below Normal Or Open Circuit Data Erratic, Intermittent Or Incorrect Voltage Above Normal, Or Shorted To High Source Voltage Below Normal, Or Shorted To Low Source Current Below Normal Or Open Circuit Condition Exists 520204 15 520204 17 520207 520207 520207 520209 520209 520209 520209 520275 3 4 5 2 3 4 5 31 Data Erratic, Intermittent Or Incorrect Bad Intelligent Device Or Component Data Erratic, Intermittent Or Incorrect Voltage Above Normal, Or Shorted To High Source Voltage Below Normal, Or Shorted To Low Source Abnormal Frequency Or Pulse Width Or Period Condition Exists Condition Exists 520276 520276 520277 520277 520277 520277 520277 520278 2 12 2 3 4 8 31 31 Condition Exists 520279 31 Condition Exists 520280 31 Condition Exists 520281 31 Condition Exists 520282 31 Data Erratic, Intermittent Or Incorrect Voltage Above Normal, Or Shorted To High Source Voltage Below Normal, Or Shorted To Low Source 520283 520283 520283 2 3 4 47 FEATURES AND CONTROLS Instrument Cluster Diagnostic Display Code Definitions Diagnostic Codes Component Throttle Body Control - Position Deviation Fault ECU Monitoring Error ECU Monitoring Error (Level 3) ECU Monitoring of Injection Cut Off (Level 1) ECU Monitoring of Injection Cut Off (Level 2) Throttle Body Control - Requested Throttle Angle Not Plausible ECU ADC Fault - No Load ECU ADC Fault - Voltage Accelerator Sensor Sync Fault - Sensor Diff Exceeds Limit ECU Fault - ICO ECU Fault - Hardware Disruption Idle Fuel Correction Bank 1 Adaptive Fuel Correction Bank 1 48 SPN FMI Condition Exists Condition 520284 31 Condition Exists Condition Exists Condition Exists 520286 520287 520288 31 31 31 Condition Exists 520289 31 Condition Exists 520305 31 Condition Exists Condition Exists Condition Exists 520306 520307 520308 31 31 31 Condition Exists Condition Exists Data Valid But Above Normal Operating Range - Least Severe Data Valid But Below Normal Operating Range - Least Severe Data Valid But Above Normal Operating Range - Least Severe Data Valid But Below Normal Operating Range - Least Severe 520309 520311 520342 31 31 15 520342 17 520344 15 520344 17 OPERATION WARNING Failure to operate the vehicle properly can result in a collision, loss of control, accident or rollover, which may result in serious injury or death. Read and understand all safety warnings outlined in the safety section of this owner’s manual. Vehicle Break-in Period The break-in period for your new POLARIS vehicle is the first 25 hours of operation, or the time it takes to use the first two tanks full of gasoline. No single action on your part is as important as a proper breakin 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 throttle or high speeds during the first three hours of use. Use of any improper oils may cause serious engine damage. POLARIS PS-4 Full Synthetic 5W-50 4-Cycle Oil is specifically formulated for your 4-cycle engine. 49 OPERATION Vehicle Break-in Period Engine and Drivetrain Break-in 1. Fill the fuel tank with gasoline. See page 28. Always exercise extreme caution whenever handling gasoline. 2. Check the oil level. See page 88 (325) or page 91 (570). Add the recommended oil as needed to maintain the oil level in the safe operating range. 3. Complete the New Operator Driving Procedures outlined on pages 56-57. 4. Avoid aggressive use of the brakes. 5. Vary throttle positions. Do not operate at sustained idle. 6. Pull only light loads. 7. Perform regular checks on fluid levels, controls and areas outlined on the daily pre-ride inspection checklist. See page 51. 8. During the break-in period, change 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. Brake System Break-in Apply only moderate braking force for the first 50 stops. Aggressive or overly forceful braking when the brake system is new could damage brake pads and rotors. 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 recommended. Pull only light loads. Avoid aggressive acceleration and high speed operation during the break-in period. If a belt fails, always clean any debris from the PVT intake and outlet duct and from the clutch and engine compartments when replacing the belt. 50 OPERATION Pre-Ride Inspection Failure to inspect and verify that the vehicle is in safe operating condition before operating increases the risk of an accident. Always inspect the vehicle before each use to make sure it's in safe operating condition. Item Brake system/pedal travel Brake fluid Front suspension Rear suspension Steering Tires Remarks Ensure proper operation Ensure proper level Inspect, lubricate if necessary Inspect, lubricate if necessary Ensure free operation Inspect condition and pressure Wheels/fasteners Frame nuts, bolts, fasteners Fuel and oil Inspect, ensure fastener tightness Inspect, ensure tightness Coolant level Coolant hoses Throttle Indicator lights/switches Air filter, pre-filter Intake pre-filters Headlamps Ensure proper level Inspect for leaks Ensure proper operation Ensure proper operation Inspect, clean Inspect, clean Check operation, apply POLARIS dielectric grease when lamp is replaced Check operation, apply POLARIS dielectric grease when lamp is replaced Push down on the seat back to ensure the latch is secure Check length of belt for damage, check latches for proper operation Check for wear or damage, ensure proper installation Brake light/tail lamps Seat Latch Seat Belt Cab Nets Ensure proper levels Page 33 111 112 85 85 114 12 115 115 39 88, 91 101-102 109 31 106 107 117 119 28 29 27 51 OPERATION Safe Operation Practices 1. Visit the Recreational Off-Highway Vehicle Association web site and take the free on-line training course. Complete the recommended safety training before operating this vehicle. Visit www.rohva.org or call 866-267-2751. 2. Do not allow anyone under 16 years of age or without a valid driver’s license to operate this vehicle. 3. Never carry a passenger on this vehicle. 4. Engine exhaust fumes are poisonous. Never start the engine or let it run in an enclosed area. 5. Never operate with accessories not approved by POLARIS for use on this vehicle. 6. Operate this vehicle off-road only. Never operate this vehicle on any public street, road or highway, including dirt and gravel roads (unless designated for off-highway use). 7. 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. 8. Always operate at a speed that's appropriate for the terrain, the visibility and operating conditions and your skills and experience. Never operate at excessive speeds. Never attempt wheelies, jumps, or other stunts. Keep both hands on the steering wheel during operation. 9. Never consume alcohol or drugs before or while operating this vehicle. 10. Always use the size and type of tires specified for your vehicle. Always maintain proper tire pressure. 11. Never operate a damaged vehicle. After any rollover or accident, have a qualified service dealer inspect the entire machine for possible damage. 52 OPERATION Safe Operation Practices 12. Never operate the vehicle on a frozen body of water unless you have first verified that the ice is sufficiently thick to support the weight and moving force of the vehicle, you and your cargo, together with any other vehicles in your party. 13. Do not touch hot exhaust system components. Always keep combustible materials away from the exhaust system. 14. Always remove the ignition key when the vehicle is not in use to prevent unauthorized use. Know Your Riding Area/Tread Lightly Familiarize yourself with all laws and regulations concerning the operation of this vehicle in your area. Respect the environment in which you ride your vehicle. Find out where the designated riding areas are by contacting your POLARIS 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 example) for others to follow. Tread lightly. Operate with respect for the terrain, avoid littering, and always stay on the designated trails. Trail Etiquette Always practice good etiquette when riding. Allow a safe distance between your vehicle and other vehicles operating in the same area. Communicate to oncoming operators by signaling the number of vehicles in your group. When stopping, move your vehicle to the edge of the trail as far as possible to allow others to pass safely. 53 OPERATION Starting the Engine 1. Position the vehicle on a level surface outdoors or in a wellventilated area. 2. Sit in the driver's seat and fasten the seat belt. Secure the cab nets. 3. Place the transmission in PARK. 4. Apply the brakes. Do not press the throttle pedal while starting the engine. 5. Turn the ignition key to the START position. Engage the starter for a maximum of five seconds. Release OFF START the key when the engine starts. Turn the key to either LIGHTS ON or LIGHTS OFF. 6. If the engine does not start within five seconds, return the ignition switch to the OFF position and wait five seconds. Repeat steps 5 and 6 until the engine starts. 7. Vary the engine RPM slightly with the throttle to aid in warm up until the engine idles smoothly. NOTICE: Operating the vehicle immediately after starting could cause engine damage. Allow the engine to warm up for several minutes before operating the vehicle. 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. 54 OPERATION Stopping the Engine 1. Release the throttle pedal completely and brake to a complete stop. 2. Place the transmission in PARK. 3. Turn the engine off. Braking 1. Release the throttle pedal completely. (When the throttle pedal is released completely and engine speed slows to near idle, the vehicle has no engine braking.) 2. Press on the brake pedal 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 other structure, be sure that the structure is well ventilated and that the vehicle is not close to any source of flame or sparks, including any appliance with pilot lights. 2. Place the transmission in PARK. 3. Turn the engine off. 4. Remove the ignition key to prevent unauthorized use. 55 OPERATION New Operator Driving Procedures 1. Read and understand the owner's manual and all warning and instruction labels before operating this vehicle. 2. Visit the Recreational Off-Highway Vehicle Association web site and take the free on-line training course. Visit www.rohva.org or call 866-267-2751. Hands-on training is also available through ROHVA. 3. Perform the pre-ride inspection. See page 51. 4. Do not tow or carry cargo during this period. 5. Select an open area that allows room to familiarize yourself with vehicle operation and handling. 6. The driver must wear helmet, eye protection, gloves, long-sleeve shirt, long pants, over-the-ankle boots and seat belt at all times. 7. Sit in the driver's seat and fasten the seat belt. 8. Make sure all cab nets are properly secured. 9. Place the transmission in PARK. 10. Start the engine. 56 OPERATION New Operator Driving Procedures 11. Apply the brakes and shift into low gear. 12. Check your surroundings and determine your path of travel. 13. Keeping both hands on the steering wheel, slowly release the brakes and depress the throttle with your right foot to begin driving. 14. Drive slowly at first. On level surfaces, practice starting, stopping, turning, maneuvering, using the throttle and brakes and driving in reverse. Learn how the vehicle handles when making both left and right turns at a slow speed. WARNING! Operating in TURF mode (if equipped) when on sloped, uneven, or loose terrain could cause loss of control and result in serious injury or death. One rear wheel may slip and lose traction or may lift up and grab when it touches the ground again. 15. Increase speed only after mastering all maneuvers at a slow speed. 16. After you become skilled at making turns and begin to operate at faster speeds, follow these precautions: • Avoid sharp turns. • Never turn while applying heavy throttle. • Never make abrupt steering maneuvers. • Operate at speeds appropriate for your skills, the conditions and the terrain. • DO NOT do power slides, “donuts”, jumps or other driving stunts. 57 OPERATION Turning the Vehicle Your vehicle is equipped 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. To turn the vehicle, rotate the steering wheel in the direction of the turn. Practice making turns at slow speeds before attempting to turn at faster speeds. WARNING! Turning improperly can result in vehicle rollover. Never turn abruptly or at sharp angles. Never turn at high speeds. 58 OPERATION Driving on Slippery Surfaces Sideways skid Turn in direction of skid When driving on slippery surfaces such as wet trails, loose gravel, or ice, be alert for the possibility of skidding and sliding. Follow these precautions when encountering slippery conditions: 1. Do not operate on excessively rough, slippery or loose terrain. 2. Slow down before entering slippery areas. 3. Maintain a high level of alertness, reading the trail and avoiding quick, sharp turns, which can cause skids. 4. Engage all-wheel drive before wheels begin to lose traction. NOTICE: Severe damage to the drive train may occur if the AWD is engaged while the wheels are spinning. Always allow the wheels to stop spinning before engaging AWD. 5. Correct a skid by turning the steering wheel in the direction of the skid. Never apply the brakes during a skid. 59 OPERATION Driving Uphill Whenever traveling uphill, follow these precautions: 1. Always check the terrain carefully before ascending any hill. Never drive on hills with excessively slippery or loose surfaces. 2. Never operate in TURF mode (if equipped) while operating on a hill or other irregular terrain. Always move the AWD switch to AWD before ascending or descending a hill. 3. Avoid excessively steep hills. If ascending a steeper grade is unavoidable, engage all-wheel drive before ascending. 4. Drive straight uphill. 5. Proceed at a steady rate of speed and throttle opening. Never open the throttle suddenly. 6. Avoid unnecessary changes in speed or direction. 7. Never go over the crest of a hill at high speed. An obstacle, a sharp drop, or another vehicle or person could be on the other side of the hill. 8. If the vehicle stalls while climbing a hill, apply the brakes. Place the transmission in reverse and slowly allow the vehicle to roll straight downhill while applying light brake pressure to control speed. 60 OPERATION Driving on a Sidehill (Sidehilling) Driving on a sidehill is not recommended. Improper procedure could cause loss of control or rollover. Avoid crossing the side of any hill unless absolutely necessary. If crossing a hill is unavoidable, follow these precautions: 1. Engage all-wheel drive. 2. Never operate in TURF mode (if equipped) while operating on a hill or other irregular terrain. Always move the AWD switch to AWD before ascending or descending a hill. 3. Drive slowly and use extreme caution. 4. If the vehicle begins to overturn, or if it feels as if it may overturn, immediately turn downhill. 5. Avoid obstacles and changes in terrain that may lower or raise one side of the vehicle or cause the vehicle to slide. 6. If the vehicle begins to slide downhill, immediately turn downhill to stop the slide, or stop the vehicle and maneuver slowly and carefully until the vehicle can be driven straight downhill. 61 OPERATION Driving Downhill Whenever descending a hill, follow these precautions: 1. Avoid excessively steep hills. 2. Never operate in TURF mode (if equipped) while operating on a hill or other irregular terrain. Always move the AWD switch to AWD before ascending or descending a hill. 3. Slow down. Never travel down a hill at high speed. 4. Always check the terrain carefully before descending a hill. Never drive on hills with excessively slippery or loose surfaces. 5. Always descend a hill with the transmission in forward gear. Never descend a hill with the transmission in neutral. 6. Avoid traveling down a hill at an angle, which would cause the vehicle to lean sharply to one side. Travel straight downhill. 7. Apply the brakes lightly to aid in slowing. 62 OPERATION Driving Through Water Your vehicle can operate through water with a maximum recommended depth equal to floor level. Follow these precautions when operating through water: 1. Determine water depth and current before entering water. 2. Choose a crossing where the water level is lowest and where both banks have gradual inclines. Never operate in water that exceeds the maximum recommended depth. Floor Level WARNING! The large tires on your vehicle may cause the vehicle to float in deep or fast-flowing water, which could result in loss of traction, loss of control, rollover or accident. 3. Wet brakes may have reduced stopping ability. After leaving water, test the brakes. Apply them lightly several times while driving slowly. The friction will help dry out the pads. NOTICE: Major engine damage can result if the vehicle is not thoroughly inspected after operation in water. Perform the services outlined in the maintenance chart. See page 81. Give special attention to engine oil, transmission oil, demand drive fluid, rear gearcase oil (if equipped) and all grease fittings. If your vehicle becomes immersed or is operated in water that exceeds the floor level, service is required before starting the engine. Your POLARIS dealer can provide this service. If it's impossible to bring the vehicle in before starting the engine, perform the service outlined on page 119, and take the vehicle in for service at the first opportunity. 63 OPERATION Driving Over Obstacles Follow these precautions when operating over obstacles: 1. Always check for obstacles before operating in a new area. 2. Look ahead and learn to read the terrain. Be constantly alert 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. Avoid operating over large obstacles such as large rocks and fallen trees. If unavoidable, use extreme caution and operate slowly. 64 OPERATION Driving in Reverse Follow these precautions when operating in reverse: 1. Always check for obstacles or people behind the vehicle. 2. Apply the throttle lightly. Never apply throttle suddenly. 3. Back slowly. 4. Apply the brakes lightly for stopping. 5. Avoid making sharp turns. Parking on an Incline A rolling vehicle can result in serious injury. Avoid parking on an incline. If parking on an incline is unavoidable, follow these precautions: 1. Place the transmission in PARK. 2. Turn the engine off. 3. Block the rear wheels on the downhill side, or park the vehicle in a sidehill position instead. 65 OPERATION Hauling Cargo WARNING Overloading the vehicle or carrying or towing cargo improperly can alter vehicle handling and may cause loss of control or brake instability. Always follow these precautions when hauling cargo: Never exceed the stated load capacity for this vehicle. REDUCE SPEED AND ALLOW GREATER DISTANCES FOR BRAKING WHEN HAULING CARGO. NEVER EXCEED THE MAXIMUM WEIGHT CAPACITY of the vehicle. When determining the weight you are adding to the vehicle, include the weight of the operator, accessories, loads in the rack or box and the load on the trailer tongue. The combined weight of these items must not exceed the maximum weight capacity. Always load the cargo box with the load as far forward and as low as possible. When operating over rough or hilly terrain, reduce speed and cargo to maintain stable driving conditions. Always operate the vehicle with extreme care when hauling or towing loads. Slow down and drive in the lowest gear available. 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 be centered, securely fasten the load and operate with extra caution. Always attach the tow load to the hitch point designated for your vehicle. HEAVY LOADS CAN CAUSE BRAKING AND CONTROL PROBLEMS. Use extreme caution when applying brakes with a loaded vehicle. Avoid terrain or situations that may require backing downhill. USE EXTREME CAUTION when operating with loads that extend over the rack sides. Stability and maneuverability may be adversely affected, causing vehicle rollover. DO NOT TRAVEL FASTER THAN THE RECOMMENDED SPEEDS. Vehicle should never exceed 10 MPH (16 km/h) while towing a load on a level grass surface. Vehicle speed should never exceed 5 MPH (8 km/h) when towing loads in rough terrain, while cornering, or while ascending or descending a hill. Never exceed 43 MPH (70 km/h) if total payload exceeds 335 lbs. (152 kg). Carrying a passenger in the cargo box could result in a fall from the vehicle or contact with moving components. Never allow a passenger to ride in the cargo box. 66 OPERATION Hauling Cargo Your POLARIS vehicle has been designed to carry or tow specific capacities. Reduce speed and allow a greater distance for braking when carrying cargo. Loads should be centered and carried as low as possible in the box. For stability on rough or hilly terrain, reduce both speed and cargo. Exercise caution if the cargo load extends over the side of the box. Always read and understand the load distribution warnings listed on warning labels and in this manual. Never exceed the maximum capacities specified for your vehicle. See page 132. Belt Life To extend belt life, use low gear when hauling or towing heavy cargo. Towing an ACE Towing this vehicle is not recommended. Always transport the vehicle on a trailer or flatbed with all four wheels off the ground. See page 131. If towing a disabled vehicle is unavoidable, place the disabled vehicle’s transmission in neutral. Tow the shortest distance possible. Do not operate faster than 10 MPH (16 km/h). 67 OPERATION Towing Loads WARNING Towing improperly can alter vehicle handling and may cause loss of control or brake instability. Always follow these precautions when towing: 1. Never load more than 150 lbs. (68.1 kg) tongue weight on the towing bracket. 2. When towing a disabled vehicle, place the disabled vehicle’s transmission in neutral. Do not operate the vehicle faster than 10 MPH (16 km/h) when towing. 3. Towing a trailer increases braking distance. Do not operate the vehicle faster than 10 MPH (16 km/h) when towing. 4. Do not tow more than the recommended weight for the vehicle. 5. Attach a trailer to the trailer hitch bracket only. Do not attach a trailer to any other location, which could result in loss of control of the vehicle. 6. The total load (operator, accessories, cargo and weight on hitch) must not exceed the maximum weight capacity of the vehicle. 68 Total Towed Load Weight (Level Ground) Total Towed Load Weight (15° grade) Total Hitch Vertical Weight Maximum Towing Speed 1500 lbs. (681 kg) 850 lbs. (386 kg) 150 lbs. (68.1 kg) 10 MPH (16 km/h) WINCH GUIDE These safety warnings and instructions apply if your vehicle came equipped with a winch or if you choose to add an accessory winch to your vehicle. WARNING Improper winch use can result in SEVERE INJURY or DEATH. Always follow all winch instructions and warnings in this manual. Your winch may have a cable made of either wire rope or specially designed synthetic rope. The term “winch cable” will be used for either unless noted otherwise. Winch Safety Precautions 1. 2. 3. 4. 5. 6. 7. 8. 9. Read all sections of this manual. Never use alcohol or drugs before or while operating the winch. Never allow children under 16 years of age to operate the winch. Always wear eye protection and heavy gloves when operating the winch. Always keep body, hair, clothing and jewelry clear of the winch cable, fairlead and hook when operating winch. Never attempt to “jerk” a load attached to the winch with a moving vehicle. See the Shock Loading section on page 78. Always keep the area around the vehicle, winch, winch cable, and load clear of people (especially children) and distractions while operating the winch. Always turn the vehicle ignition power OFF when it and the winch are not being used. 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 allows the drum to pull on the winch cable and move the load. 69 WINCH GUIDE Winch Safety Precautions 10. Always apply your vehicle’s park brake and/or park mechanism to hold the vehicle in place during winching. Use wheel chocks if needed. 11. Always align the vehicle and winch with the load directly in front of the vehicle as much as possible. Avoid winching with the winch cable at an angle to the winching vehicle’s centerline whenever possible. 12. If winching at an angle is unavoidable, follow these precautions: A. B. Look at the winch drum occasionally. Never let the winch cable “stack” or accumulate at one end of the winch drum. Too much winch cable at one end of the winch drum can damage the winch and the winch cable. If stacking occurs, stop winching. Follow step 15 on page 76 to feed and rewind the cable evenly before continuing the winch operation. 13. Never winch up or down at sharp angles. This can destabilize the winching vehicle and possibly cause it to move without warning. 14. Never attempt to winch loads that weigh more than the winch’s rated capacity. 15. The winch motor may become hot during winch use. If you winch for more than 45 seconds, 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 load. 17. Never let the winch cable run through your hands, even if wearing heavy gloves. 70 WINCH GUIDE Winch Safety Precautions 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 winch and winch cable before each use. 23. Never winch the hook fully into the winch. This can cause damage to winch components. 24. Unplug the remote control from the vehicle when the winch is not in use to prevent inadvertent activation and use by unauthorized persons. 25. Never grease or oil the winch cable. This will cause the winch cable to collect debris that will shorten the life of the cable. 71 WINCH GUIDE Winch Operation Read the Winch Safety Precautions in the preceding pages before using your winch. Tip: Consider practicing the operation and use of your winch before you actually need to use it in the field. WARNING Improper winch use can result in SEVERE INJURY or DEATH. Always follow all winch instructions and warnings in this manual. Each winching situation is unique. • Take your time to think through the winching you are about to do. • Proceed slowly and deliberately. • Never hurry or rush during winching. • Always pay attention to your surroundings. • You may need to change your winching strategy if it is not 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 meter) of winch cable if the winch is being used (or has been used) for lifting an accessory plow assembly. Promptly replace any worn or damaged cable. 2. Never operate a winch or a vehicle in need of repair or service. 3. Always apply your vehicle’s park brake and/ or park mechanism to hold the vehicle in place during Hook Strap winching. Use wheel chocks if needed. 72 WINCH GUIDE Winch Operation 4. Always use the hook strap when handling the hook. WARNING! Never put your fingers into the hook. This could lead to SEVERE INJURY. A. Attach the hook itself onto the load or use a tow strap or chain NO YES to secure the load to the winch cable. Tip: A “tow strap” is NOT intended to stretch. A “recovery strap” is designed to stretch. WARNING! Never use a recovery strap when winching due to the excessive energy that can be released if the winch cable breaks. This can result in SEVERE INJURY or DEATH. See the Shock Loading section on page 78. B. Never hook the winch cable back onto itself. This will damage the winch cable and may result in winch cable failure. WARNING! Replace the winch cable at the first sign of damage to prevent SEVERE INJURY or DEATH in the event of failure. For your safety, always replace POLARIS winch parts (including the cable) with genuine POLARIS replacement parts available at your authorized POLARIS dealer. C. If possible, keep the winch cable aligned with the centerline of the winching vehicle. This will help the spooling of the winch cable and reduce the load on the fairlead. D. 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 TreadLightly® (treadlightly.org). E. Before operating the winch, be sure that the safety latch on the winch cable hook is fully seated when the load is attached. F. Never operate your winch with a damaged hook or latch. Always replace damaged parts before using NO YES the winch. 73 WINCH GUIDE Winch Operation 5. Never remove the hook strap from the hook. 6. 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 wrapped around the winch drum at all times. The friction provided by this wrapped cable allows the drum to pull on the winch cable and move the load. 8. Read and adhere to the following information for winch damping to ensure safe winch use. A. B. C. D. In order to absorb energy that could be released by a winch cable failure, always place a “damper” on the winch cable. A damper can be a heavy jacket, tarp, or other soft, dense object. A damper can absorb much of the energy released if a winch cable breaks when winching. Even a tree limb can help as a damper if no other items are available to you. Lay the damper on top of the mid-point of the winch cable length that is spooled out. On a long pull, it may be necessary to stop winching so that the damper can be repositioned to the new mid-point of the winch cable. Always release the tension on the winch cable before repositioning the damper. Avoid being directly in line with the winch cable whenever possible. Also, never permit others to stand near or in line with the winch cable during winch operation. 9. Never hook the winch cable back onto itself. This will damage the winch cable and may result in winch cable failure. 10. Never use straps, chains or other rigging items that are damaged or worn. 74 WINCH GUIDE Winch Operation 11. The ONLY time a winch-equipped vehicle should be moving when using the winch is when that vehicle itself is stuck. The winchequipped 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 78. For your safety, always follow these guidelines when 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 winch cable hook to the anchor point or the stuck vehicle’s frame following instructions in this manual. D. Re-engage the clutch on the winch. E. Slowly winch in the slack in the winch cable. F. Select the proper vehicle gear to propel the stuck vehicle in the direction of winching. G. Shift to the lowest gear available on the stuck vehicle. H. Slowly and carefully apply vehicle throttle and winch together to free the vehicle. I. Stop winching as soon as the stuck vehicle is able to propel itself without the help of the winch. J. Detach the winch cable hook. K. Rewind the winch cable evenly back onto the winch drum following the instructions in this manual. 12. Never attempt to winch another stuck vehicle by attaching the winch cable to a suspension component, brush guard, bumper or cargo rack. Vehicle damage may result. Instead, attach the winch to a strong portion of the vehicle frame or hitch. 13. Extensive winching will run down the battery on the winching vehicle. Let the winching vehicle’s engine run while operating the winch to prevent the battery from running low if winching for long periods. 75 WINCH GUIDE Winch Operation 14. The winch motor may become hot during winch use. If you winch for more than 45 seconds, or if the winch stalls during operation, stop winching and permit the winch to cool down for 10 minutes before using it again. 15. After winching is 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. B. C. D. E. F. 76 Release the clutch on the winch. Feed out the winch cable that is unevenly bunched up in one area. Re-engage the winch clutch. Have an assistant pull the winch cable tightly with about 100 lbs. (45 kg) of tension using the hook strap. Slowly winch the cable in while your assistant moves the end of the winch cable back and forth horizontally to evenly distribute the winch cable on the drum. Doing this reduces the chances of the winch cable “wedging” itself between lower layers of winch cable. WINCH GUIDE Winch Cable Care For your safety, always replace POLARIS winch parts (including the cable) with genuine POLARIS replacement parts available at your authorized POLARIS dealer. WARNING! Use of worn or damaged cable could lead to sudden failure and SEVERE INJURY. 1. Always inspect your winch before each use. Inspect for worn or loose parts including mounting hardware. Never use the winch if any part needs repair or replacement. 2. Always inspect your winch cable before each use. Inspect for worn or kinked winch cable. A. B. C. D. A kinked winch cable made of wire rope is shown at right. Even after being “straightened out,” this cable has already been permanently and severely A 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 at B 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 at right). C Promptly discontinue use of a winch cable in this condition. Also replace the winch cable if there are fused or melted fibers. Such an area of the synthetic rope will be stiff and appear smooth or glazed. Promptly discontinue use of a winch cable in this condition. 77 WINCH GUIDE Shock Loading WARNING! Your winch cable is very strong but it is NOT designed for dynamic, or “shock” loading. Shock loading may tension a winch cable beyond its strength and cause the cable to break. The end of a broken winch cable under such high loading can cause SEVERE INJURY or DEATH to you and other bystanders. Winch cables are designed to NOT absorb energy. This is true of both wire-rope and synthetic-rope winch cables. 1. Never attempt to “jerk” a load with the winch. For example, never take up slack in the winch cable by moving the winching vehicle in an attempt to move an object. This is a dangerous practice. It generates high winch cable loads that may exceed the strength of the cable. Even a slowly moving vehicle can create large shock loads in a winch cable. WARNING! SEVERE INJURY or DEATH can result from a broken winch cable. 2. Never quickly turn the winch ON and OFF repeatedly (“jogging”). This puts extra 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 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 recovery straps with your winch. Recovery straps are designed to stretch and can store energy. This stored energy in the recovery strap is released if a winch cable fails making the event even more hazardous. Similarly, never use elastic “bungie” cords for winching. 5. Never use the winch to tie down a vehicle to a trailer or other transportation vehicle. This type of use also causes shock loading that can cause damage to the winch, winch cable, or vehicles used. Your winch cable is designed and tested to withstand the loads produced by the winch motor when operated from a stationary vehicle. Always remember that the winch and winch cable are NOT designed for shock loading. 78 WINCH GUIDE Winch Maintenance and Service Safety WARNING! Improper or lack of winch maintenance and service could lead to SEVERE INJURY or DEATH. Always follow all winch instructions and warnings in this manual. 1. Always inspect your winch before each use. Inspect for worn or kinked winch cable. Also inspect for worn or loose parts including mounting hardware. 2. Permit your winch motor to cool down prior to servicing your winch. 3. Never work on your winch without first disconnecting the battery connections to prevent accidental activation of the winch. 4. For your safety, always replace POLARIS winch parts (including the cable) with genuine POLARIS replacement parts available at your authorized POLARIS dealer. 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 store. Although they may look similar, they are NOT alike. A polymer rope not designed for winch use will stretch and store excessive energy when winching. WARNING! Failure of a stretched rope under winching conditions will release all of the stored energy. This will increase the chances of SEVERE INJURY or DEATH. 79 EMISSION CONTROL SYSTEMS Noise Emission Control System Do not modify the engine, intake or exhaust components, as doing so may affect compliance with U.S.A. EPA noise control requirements (40 CFR 205) and local noise level requirements. Operation on Public Lands in the U.S.A. Your POLARIS vehicle has a spark arrester that was tested and qualified to be in accordance with the USFS standard 5100-1C. Federal law requires that this spark arrester be installed and functional when the vehicle is operated on public lands. Operation of off-road vehicles on public lands in the U.S.A. is regulated by 43 CFR 420. Violations are subject to monetary penalties. Federal regulations can be viewed online at www.gpoaccess.gov/ecfr/. Crankcase Emission Control System This engine is equipped with a closed crankcase system. Blow-by gases are forced back to the combustion chamber by the intake system. All exhaust gases exit through the exhaust system. Exhaust Emission Control System Exhaust emissions are controlled by engine design. An electronic fuel injection (EFI) system controls fuel delivery. The engine and EFI components are set at the factory for Emissions Label optimal performance and are not (inside of frame tube) adjustable. The emissions label is located on the inside of the lower left frame tube (below driver’s foot area). Electromagnetic Interference This spark ignition system complies with Canadian ICES-002. This vehicle complies with the EMC requirements of European directives 97/24/EC and 2004/108/EC. Non-ionizing Radiation: This vehicle emits some electromagnetic energy. People 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. 80 MAINTENANCE Periodic Maintenance Chart Any qualified repair shop or person may maintain, replace or repair the emission control devices or systems on your vehicle. An authorized POLARIS dealer can perform any service that may be necessary for your vehicle. POLARIS also recommends POLARIS parts for emissions-related service, however equivalent parts can be used. It is a potential violation of the Clean Air Act if a part supplied by an aftermarket parts manufacturer reduces the effectiveness of the vehicle’s emission controls. Tampering with emission controls is prohibited by federal law. Owners are responsible for performing the scheduled maintenance identified in this owner’s manual. Careful periodic maintenance will help keep your vehicle in the safest, most reliable condition. Inspection, adjustment and lubrication of important components are explained in the periodic maintenance chart. Inspect, clean, lubricate, adjust and replace parts as necessary. When inspection reveals the need for replacement parts, genuine POLARIS parts are available from your POLARIS dealer. Equivalent parts may be used for emissions-related service. Service and adjustments are important for proper vehicle operation. If you're not familiar with safe service and adjustment procedures, a qualified dealer can perform these operations. Vehicles subjected to heavy or severe use patterns must be inspected and serviced more frequently. Severe Use Definition • Frequent immersion in mud, water or sand • Frequent or prolonged operation in dusty environments • Racing or race-style high RPM use • Prolonged low speed, heavy load operation • Extended idle • Short trip cold weather operation Pay special attention to the oil level. A rise in oil level during cold weather can indicate contaminants collecting in the oil sump or crankcase. Change oil immediately if the oil level begins to rise. Monitor the oil level, and if it continues to rise, discontinue use and determine the cause. Your POLARIS dealer can assist 81 MAINTENANCE Periodic Maintenance Chart Maintenance Chart Key Symbol Description Ź Perform these operations more often for vehicles subjected to severe use. D Have an authorized POLARIS dealer or other qualified person perform these services. WARNING! Improperly performing the procedures marked with a “D” could result in component failure and lead to serious injury or death. Have an authorized POLARIS dealer or other qualified person perform these services. Perform all services at whichever maintenance interval is reached first. Record maintenance and service in the Maintenance Log beginning on page 146. Item Steering Front suspension Rear suspension Tires Brake fluid level Brake pedal travel Brake system Wheels/fasteners Frame fasteners Engine oil level Intake pre-filters Winch (if equipped) Coolant Power steering unit (if equipped) Headlamp/tail lamp Ź Air filter, main element Ź Brake pad wear D Ź Engine breather Battery Fuel System 82 Maintenance Interval (whichever comes first) Hours Calendar Miles (Km) Inspect and make adjustments as need ed. See Pre-Ride Checklist on page 51. Pre-Ride - Remarks - See pages 69-79 - Daily Daily - Check level Inspect daily; clean often - Daily - - Weekly - Check operation; apply dielectric grease if replacing Inspect; replace as needed 10 H Monthly 100 (160) Inspect periodically 25 H 25 H 25 H Monthly Monthly Monthly 150 (250) 250 (400) - Inspect; replace if necessary Check terminals; clean; test Inspect; cycle key to pressurize fuel pump; check lines and fittings for leaks and abrasion MAINTENANCE Periodic Maintenance Chart Item Maintenance Interval Remarks (whichever comes first) Hours Calendar Miles (Km) Ź Engine oil change 25 H 1M - Break-in oil and filter change Ź Demand drive fluid 25 H 1M - Break-in oil level check Ź Transmission oil (main gearcase) 25 H 1M - Break-in oil level check Ź Throttle cable 50 H 6M 300 (500) Inspect; adjust; lubricate; replace if necessary Throttle body air intake ducts/flange 50 H 6M 300 (500) Inspect duct for proper sealing/air leaks Ź General lubrication 50 H 3M 500 (800) Lubricate all fittings, pivots, cables, etc. Ź Oil lines, fasteners (if equipped) 50 H 6M 500 (800) Inspect for leaks and loose fittings Inspect, lubricate, adjust 50 H 6M 500 (800) D Steering Shift Linkage 50 H 6M 500 (800) Lubricate Ź Front Suspension 50 H 6M 500 (800) Lubricate Ź Rear Suspension 50 H 6M 500 (800) Lubricate Cooling system 50 H 6M 500 (800) Inspect coolant strength seasonally; pressure test system yearly Ź Engine oil change 100 H 6M 1000 (1600) Change the oil and filter 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 pump; replace lines every two years Ź Spark plug 100 H 12 M 600 (1000) Inspect; replace as needed Ź Demand drive fluid 100 H 12 M - Change fluid Ź Transmission oil (main gearcase) 100 H 12 M - Change fluid Ź Radiator 100 H 12 M 1000 (1600) Inspect; clean external surfaces Ź Cooling Hoses 100 H 12 M 1000 (1600) Inspect for leaks Ź Engine mounts 100 H 12 M 1000 (1600) Inspect 100 H 12 M 1000 (1600) Inspect Exhaust muffler/ pipe Ź Perform these procedures more often for vehicles subjected to severe use. D Have an authorized POLARIS dealer or other qualified person perform these services. 83 MAINTENANCE Periodic Maintenance Chart Item Maintenance Interval (whichever comes first) Remarks Hours Calendar Miles (Km) Ź 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 and driven) 100 H 12 M 1000 (1600) Inspect; clean; replace worn parts Drive belt 100 H 12 M 1000 (1600) Inspect; replace as needed D Front 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 Suspension bushings 250 H 24 M 2000 (3200) Inspect; replace if necessary Spark arrester 300 H 36 M 3000 (4800) Clean out - 60 M 500 H - Ź Coolant Ź Valve clearance D Toe adjustment Headlight aim - Replace coolant 5000 (8000) Inspect; adjust as needed - Inspect periodically; adjust when parts are replaced - Adjust as needed Ź Perform these procedures more often for vehicles subjected to severe use. D Have an authorized POLARIS dealer or other qualified person perform these services. 84 MAINTENANCE Lubrication Recommendations Check and lubricate all components at the intervals outlined in the Periodic Maintenance Chart beginning on page 81, or more often under severe use, such as wet or dusty conditions. Items not listed in the chart should be lubricated at the general lubrication interval. Item Lube Method Engine Oil PS-4 5W-50 4-Cycle Oil Add to proper level on dipstick. See page 88 (325) or page 91 (570). Brake Fluid DOT 4 Brake Fluid Maintain level between fill lines. See page 112. Transmission Oil (Main Gearcase) AGL Gearcase Lubricant & Transmission Fluid See page 95. Demand Drive Fluid (Front Gearcase) Demand Drive Fluid See page 94. Prop Shaft U-Joint Grease Locate fittings and grease. Rear Control Arm Pivot Bushings, Front A-Arm Bushings All Season Grease or grease Locate fittings and grease. conforming to NLGI No. 2 Stabilizer Bar Bushings, All Season Grease or grease Locate fittings and grease. Tie Rod Bushings, Ball conforming to NLGI No. 2 Joint Boots Prop Shaft Grease Fitting 85 MAINTENANCE Lubrication Recommendations Stabilizer Bar Bushings Rear Control Arm Pivot Bushings Front A-Arm Bushing 86 Tie Rod Bushing Ball Joint Boot MAINTENANCE Engine Oil Oil Recommendations POLARIS recommends the use of POLARIS PS-4 Full Synthetic 5W50 4-cycle oil for this engine. WARNING! Vehicle operation with insufficient, deteriorated, or contaminated engine 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 may need to be changed more frequently if POLARIS PS-4 engine oil is not used. Follow the manufacturer's recommendations for ambient temperature operation. See page 134 for the part numbers of POLARIS products. NOTICE: Mixing brands or using a non-recommended oil may cause serious engine damage. Always use the recommended oil. Never substitute or mix oil brands. 87 MAINTENANCE Engine Oil Always check and change the oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 81. Always use the recommended engine oil. See page 87. NOTICE: Allowing dirt or debris to enter the engine can result in serious engine damage. Always clean away all dirt and debris from the dipstick area before removing the dipstick. Oil Check (325) The oil dipstick is located on the lower engine, behind the seat. Access the dipstick through the right rear wheel well. Remove the dipstick to check the oil level and to add oil. An additional oil fill hole is located at the top of the engine. Add oil through either the dipstick hole or the upper fill hole. Access the upper fill hole cap through the cargo box access panel. 1. Position the vehicle on a level surface. 2. Place the transmission in PARK. 3. Always clean away all dirt and debris from the dipstick area before removing the dipstick. Remove the dipstick. Wipe it dry with a clean cloth. 4. Reinstall and tighten the dipstick. 5. Remove the dipstick and check the oil level. 6. Add the recommended fluid as needed. Maintain the oil level in the safe range between the FULL and ADD marks. Do not overfill. 7. Reinstall and tighten the dipstick. 88 Upper Oil Fill Oil Dipstick (Check/Fill) Full Add MAINTENANCE Engine Oil Oil and Filter Change (325) Always check and change the oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 81. Always change the oil filter whenever changing oil. The engine drain plug is located on the bottom of the crankcase. 1. Position the vehicle on a level surface. Place the transmission in PARK. Apply the brakes. 2. Start the engine. Allow it to idle for two to three minutes. Stop the engine. 3. Clean the area around the drain plug. CAUTION! Hot oil can cause burns to skin. Do not allow hot oil to contact skin. 4. Place a drain pan beneath engine crankcase and remove the drain plug. 5. Allow the oil to drain completely. 6. Install a new sealing washer on the drain plug. Tip: The sealing surfaces on drain plug and crankcase should be clean and free of burrs, nicks or scratches. Sealing Washer Spring Drain Plug Filter O-Ring Filter Cover 7. Reinstall the drain plug. Torque to 11-13 ft. lbs. (14.5-17.5 Nm). 89 MAINTENANCE Engine Oil Oil and Filter Change (325) 8. Using a clean, dry cloth, clean the oil filter cover on the crankcase. 9. Place shop towels beneath the filter cover to catch oil drips. Remove the cover screws and remove the cover to access the oil filter. 10. Remove the oil filter and spring, retaining the spring for reinstallation. 11. Using a clean, dry cloth, clean the surface of the crankcase. 12. Lubricate the o-ring for the new filter with a film of fresh engine oil. Check to make sure the o-ring is in good condition. Install the oring to the filter cover. 13. Reinstall the oil filter spring, then install the new filter. 14. Reinstall the oil filter cover and o-ring. Torque the screws to 88 in. lbs. (10 Nm). 15. Fill the sump with 1.75 quarts (1.65 l) of the recommended oil. 16. Reinstall the upper fill cap (if removed) and tighten the dipstick. 17. Make sure the transmission is in PARK. Apply the brakes. 18. Start the engine. Allow it to idle for one to two minutes. 19. Stop the engine. Inspect for leaks. 20. Re-check the oil level on the dipstick and add oil as necessary to bring the level to the upper mark on the dipstick. 21. Dispose of used filter and oil properly. 90 MAINTENANCE Engine Oil Always check and change the oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 81. Always use the recommended engine oil. See page 87. Oil Check (570) The oil dipstick and fill tube is located on the engine, behind the passenger seat. Access the dipstick through the right rear wheel well. 1. Position the vehicle on a level surface. 2. Place the transmission in PARK. 3. Always clean away all dirt and debris from the dipstick area before removing the dipstick. Remove the dipstick. Wipe it dry with a clean cloth. 4. Reinstall and tighten the dipstick. 5. Remove the dipstick and check the oil level. 6. Add the recommended fluid as needed. Maintain the oil level in the safe range between the FULL and ADD marks. Do not overfill. 7. Reinstall and tighten the dipstick. Dipstick Full Add 91 MAINTENANCE Engine Oil Oil and Filter Change (570) Always check and change the oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 81. Always change the oil filter whenever changing oil. The engine drain plug is located on the bottom of the crankcase. 1. Position the vehicle on a level surface. Place the transmission in PARK. Apply the brakes. 2. Start the engine. Allow it to idle for two to three minutes. Stop the engine. 3. Clean the area around the drain plug. CAUTION! Hot oil can cause burns to skin. Do not allow hot oil to contact skin. 4. Place a drain pan beneath engine crankcase and remove the drain plug. 5. Allow the oil to drain completely. 6. Reinstall the sealing washer on the drain plug. Drain Plug Access Tip: The sealing surfaces on drain plug and crankcase should be clean and free of burrs, nicks or scratches. 7. Reinstall the drain plug. Torque to 12 ft. lbs. (16 Nm). 92 MAINTENANCE Engine Oil Oil and Filter Change (570) 8. Using a cap-style oil filter wrench, turn the filter counter-clockwise to remove it. 9. Using a clean dry cloth, clean the filter sealing surface on the crankcase. Make sure the old filter o-ring is completely removed. 10. Lubricate the o-ring on the new filter with a film of fresh engine oil. Check to make Oil Filter sure the o-ring is in good condition. 11. Install the new filter and turn by hand until the filter gasket contacts the sealing surface, then turn an additional 3/4 turn. 12. Always clean away all dirt and debris from the dipstick area before removing the dipstick. Remove the dipstick and fill the sump with two quarts (1.9 l) of recommended oil. 13. Reinstall and tighten the dipstick. 14. Make sure the transmission is in PARK. Apply the brakes. 15. Start the engine. Allow it to idle for one to two minutes. 16. Stop the engine. Inspect for leaks. 17. Re-check the oil level on the dipstick and add oil as necessary to bring the level to the upper mark on the dipstick. 18. Dispose of used filter and oil properly. 93 MAINTENANCE Gearcases Demand Drive Unit (Front Gearcase) Always check and change the fluid at the intervals outlined in the Periodic Maintenance Chart beginning on page 81. Refer to the Gearcase Specifications Chart on page 96 for recommended lubricants, capacities and torque specifications. Fluid Check The fill plug is located on the bottom right side of the demand drive unit. Access the fill plug through the right front wheel well. Maintain the fluid level even with the bottom thread of the fill plug hole. 1. Position the vehicle on a level surface. 2. Remove the fill plug. Check the fluid level. 3. Add the recommended fluid to the bottom thread of the fill plug hole. 4. Reinstall the fill plug. Torque to specification. Fill Plug Fill Level Drain Plug Fluid Change The drain plug is located on the bottom of the gearcase. 1. Remove the fill plug. 2. Place a drain pan under the drain plug. 3. Remove the drain plug. Allow the fluid to drain completely. 4. Clean the drain plug. If the o-ring is damaged, install a new o-ring. 5. Reinstall the drain plug. Torque to specification. 6. Add the recommended fluid to the bottom thread of the fill plug hole. 7. Reinstall the fill plug. Torque to specification. 8. Check for leaks. Discard used fluid properly. 94 MAINTENANCE Gearcases Transmission (Main Gearcase) Always check and change the fluid at the intervals outlined in the Periodic Maintenance Chart beginning on page 81. Refer to the Gearcase Specifications Chart on page 96 for recommended lubricants, capacities and torque specifications. Fluid Check The fill plug is located on the rear of the gearcase. Maintain the fluid level at the bottom of the fill plug hole. 1. Position the vehicle on a level surface. 2. Remove the fill plug. Check the fluid level. 3. Add the recommended fluid to the bottom of the fill plug hole. Do not overfill. 4. Reinstall the fill plug. Torque to specification. Fill Plug Fluid Change The drain plug is located on the bottom of the gearcase between the rear tires. Access the drain plug through the drain hole in the skid plate. Drain Plug (between rear tires) 1. Remove the fill plug. 2. Place a drain pan under the drain plug. Remove the drain plug. Allow the fluid to drain completely. 3. Clean the drain plug. Reinstall the drain plug with a new o-ring. Torque to specification. 4. Add the recommended fluid to the bottom of the fill plug hole. Do not overfill. 5. Reinstall the fill plug. Torque to specification. 6. Check for leaks. Discard used fluid properly. 95 MAINTENANCE Gearcases Gearcase Specification Chart Use of other fluids may result in improper operation of components. See page 134 for the part numbers of POLARIS products. Gearcase Lubricant Capacity Fill Plug Torque Drain Plug/ Level Check Plug Torque Transmission (Main Gearcase) AGL Gearcase Lubricant & Transmission Fluid 44 oz. (1300 ml) 10-14 ft. lbs. (14-19 Nm) 10-14 ft. lbs. (14-19 Nm) 9 oz. (265 ml) 8-10 ft. lbs. (11-13.6 Nm) 8-10 ft. lbs. (11-13.6 Nm) Demand Drive Unit Demand Drive (Front Gearcase) Fluid Spark Plug Spark Plug Gap/Torque Electrode Gap 0.8 +/- 0.1 mm New Plug Torque 9 ft. lbs. (12 Nm) without anti-seize Used Plug Torque 9 ft. lbs. (12 Nm) without anti-seize NOTICE: Using non-recommended spark plugs can result in serious engine damage. Always use POLARIS-recommended spark plugs or their equivalent. Refer to the specifications section beginning on page 132. Spark plug condition is indicative of engine operation. The spark plug firing end condition should be read after the engine is warmed up and the vehicle is driven at higher speeds. Immediately check the spark plug for correct color. See page 97. CAUTION! A hot exhaust system and engine can cause burns. Wear protective gloves when removing a spark plug for inspection. 96 MAINTENANCE Spark Plug Spark Plug Removal and Replacement 1. Remove the cargo box access panel. 2. Remove the spark plug cap. 3. Using the spark plug wrench provided in the tool kit, remove the plug by rotating it counter-clockwise. 4. Reverse the procedure for spark plug installation. Torque to specification. See page 96. Spark Plug Condition Normal 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. Wet Fouled Plug The wet fouled insulator tip is black. A damp oil film covers the firing end. There may be a carbon layer over the entire nose. Generally, the electrodes are not worn. General causes of fouling are: incorrect spark plug type or heat range, excessive engine oil consumption or incorrect throttle body adjustments. 97 MAINTENANCE Fuses If the engine stops or will not start, or if you experience other electrical failures, a fuse may need replacement. Locate and correct any short circuits that may have caused the blown fuse, then replace the fuse. Main Fuse 20A 20A 20A 10A 20A 30A 30A 10A 15A Feature Supported Lights: Headlights, Taillights Drive: AWD Accessory: Winch Switch, 12V Power Receptacle Fuel Pump Electronic Engine Control, Starting Engine Control EPS (Optional) Constant Vehicle Power Fan Circuit Braker - Auto Reset The fuse box is located under the seat. Spare fuses are provided in the fuse box. Fuse Box 98 MAINTENANCE Fuses Fuse Box 1. Remove the seat to access the fuse box. 2. Squeeze the cover release tabs inward and remove the fuse box cover. 3. Remove the suspect fuse from the fuse panel. If the fuse is blown, install a new fuse with the same amperage rating. 4. Reinstall the fuse box cover. 5. Reinstall the seat. Release Tabs 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 thoroughly. 99 MAINTENANCE Cooling System Operation The engine coolant level is controlled or maintained by the recovery system. The recovery system components are the overflow bottle, radiator filler neck, radiator pressure cap and connecting hose. As coolant operating temperature increases, the expanding (heated) excess coolant is forced out of the radiator, past the pressure cap, and into the overflow bottle. As engine coolant temperature decreases, the contracting (cooled) coolant is drawn back up from the tank, past the pressure cap, and into the radiator. Tip: Some coolant level drop on new vehicles is normal as the system is purging itself of trapped air. Observe coolant levels and maintain as recommended by adding coolant to the overflow bottle. Adding or Changing Coolant POLARIS recommends the use of POLARIS Antifreeze 50/50 Premix. This antifreeze is already premixed and ready to use. Do not dilute with water. See page 134 for the part numbers of POLARIS products. To ensure that the coolant maintains its ability to protect the engine, we recommend that the system be completely drained every five (5) years and fresh Antifreeze 50/50 Premix added. Any time the cooling system has been drained for maintenance or repair, replace the coolant with fresh Antifreeze 50/50 Premix. 100 MAINTENANCE Cooling System Radiator and Cooling Fan Always check and clean the screen and radiator fins at the intervals outlined in the Periodic Maintenance Chart beginning on page 81. Do not obstruct or deflect air flow through the radiator by installing unauthorized accessories in front of the radiator or behind the cooling fan. Interference with the radiator air flow can lead to overheating and consequent engine damage. NOTICE: Washing the vehicle with a high-pressure hose could damage the radiator fins and impair the radiator's effectiveness. Using a highpressure system is not recommended. Radiator Coolant Level This procedure is required only if the cooling system has been drained for maintenance and/or repair. But if the overflow bottle has run dry, the level in the radiator should also be inspected. 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. Remove the front box cover and access panel. See page 26. 2. Slowly remove the radiator cap. 3. View the coolant level through the opening. 4. Use a funnel and slowly add coolant as needed. Tip: Use of a non-standard pressure cap will not allow the recovery system to function properly. Your POLARIS dealer can provide the correct replacement part. Radiator Cap Overflow Bottle 101 MAINTENANCE Cooling System Coolant Level Always check and change the coolant at the intervals outlined in the Periodic Maintenance Chart beginning on page 81. Maintain the coolant level between the minimum and maximum marks on the bottle (when the fluid is cool). The coolant level in the bottle can be viewed through the left front wheel well or in the compartment in the front box. 1. Position the vehicle on a Overflow level surface. Bottle Radiator 2. View the coolant level in Cap the overflow bottle. 3. If the coolant level is below the safe operating range, remove the cap and use a funnel to add coolant through the opening. Reinstall the cap. Tip: If coolant must be added often, or if the overflow bottle runs completely dry, there may be a leak in the system. Your POLARIS dealer can inspect the cooling system. 102 MAINTENANCE POLARIS Variable Transmission (PVT) System WARNING Failure to comply with the instructions in this warning can result in severe injury or death. Do not modify any component of the PVT system. Doing so may reduce its strength so that a failure may occur at a high speed. The PVT system has been precision balanced. Any modification will cause the system to be out of balance, creating vibration and additional loads on components. The PVT system rotates at high speeds, creating large amounts of force on clutch components. As the owner, you have the following responsibilities for your own safety and the safety of others: • Always follow all recommended maintenance procedures. Always look for and remove debris inside and around the clutch and vent system when replacing the belt. • See your POLARIS dealer, or other qualified person, for service and repair assistance. • This PVT system is intended for use on POLARIS products only. Do not install it in any other product. • Always make sure the PVT housing is securely in place during operation. 103 MAINTENANCE POLARIS Variable Transmission (PVT) System Belt Replacement/Debris Removal If a belt fails, always clean any debris from the PVT intake and outlet duct and from the clutch and engine compartments when replacing the belt. WARNING! Failure to remove ALL debris when replacing the belt could result in vehicle damage, loss of control and severe injury or death. 1. Allow hot components to cool before performing this procedure. 2. Remove the clutch cover screws and open the clutch cover. Remove all debris wrapped in and around the PVT system. 3. Remove all debris from the entire clutch air duct passage. 4. Check for signs of damage to seals on the transmission and engine. If any seals appear to be damaged, your vehicle requires prompt service that your POLARIS dealer can provide. Tip: Belt slip is responsible for creating excessive heat that destroys belts, wears clutch components and causes outer clutch covers to fail. Switch to low range while operating at slower speeds to extend the life of the PVT components (belt, cover, etc.). 104 MAINTENANCE POLARIS Variable Transmission (PVT) System PVT Drying There may be some instances when water is accidently ingested into the PVT system. Use the following instructions to dry it out before operating. NOTICE: When washing the vehicle, always avoid spraying water directly toward the PVT intake duct. See page 126 for recommended washing procedures. 1. Remove the drain plug from the bottom of the clutch box. Allow the water to drain. Reinstall the drain plug securely. 2. Place the transmission in PARK. Apply the brakes. Start the engine. 3. 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 10 seconds. Drain Plug 4. Allow the engine RPM to settle to idle speed. Apply the brakes. Shift the transmission to the lowest available range. 5. Test for belt slippage. If the belt slips, repeat the process. 6. Your vehicle requires service as soon as possible, which your POLARIS dealer can provide. 105 MAINTENANCE Air Filter Always clean all dirt and debris away from the air box area before servicing the air filter. Always change the air filter at the intervals outlined in the Periodic Maintenance Chart beginning on page 81. 1. Remove the cargo box access panel. Cover Clips (2) 2. Clean all dirt and debris from the air box area BEFORE servicing the air filter. 3. Unlatch the cover clips and carefully remove the air box cover. 4. Loosen the air filter clamp and remove the filter. NOTICE: Dirt or debris in the air box could result in severe engine damage. Always clean all dirt and debris from the air box before installing the filter. 5. Inspect the air box for dirt, debris, oil or water. Compress the edges of the air box drain to drain any water. Clean the air box thoroughly and wipe it well with a clean, dry cloth. 6. Reinstall the filter. Install a new filter if needed. Do not attempt to clean the air filter. Tighten the clamp. 7. Reinstall the air box cover and secure the cover clips. 8. Reinstall the access panel. Cover Hinges Filter Clamp Air Box Drain 106 MAINTENANCE Breather Hose Inspection 1. Remove the breather hose clamp at the engine (near the exhaust outlet). 2. Pull the other end of the breather hose assembly away from the airbox. 3. Remove the breather hose assembly from the vehicle. 4. Inspect the hoses for debris. Blow gently through the hoses to check for clogging. Replace a damaged or clogged hose. 5. Check hoses for cracks, deterioration, abrasions or leaks. Replace as needed. 6. Reinstall the hose assembly and secure the clamp at the engine. Push the other end of the hose firmly into the airbox fitting. NOTICE: Operation of the vehicle without breather hoses can cause engine damage. Always reinstall a breather hose after removing it for service. Intake Pre-Filters The engine intake pre-filter is located on the right side of the cargo box. The PVT intake pre-filter is located on the left side of the cargo box. Inspect both pre-filters before each use of the vehicle to ensure adequate air flow. If necessary, remove the pre-filters and clean with soapy water. Dry with low pressure compressed air. Engine Intake Pre-Filter NOTICE: When washing the vehicle, always avoid spraying water directly toward the PVT intake duct. See page 126 for recommended washing procedures. 107 MAINTENANCE Spark Arrester WARNING Failure to heed the following warnings while servicing the spark arrester could result in serious injury or death. Never run the engine in an enclosed area. Remove any combustible materials from the area. Wear eye protection and leather work gloves. Do not stand behind or in front of the vehicle while purging. Never go under the vehicle while it's inclined. The exhaust system can get extremely hot. Do not perform service on the spark arrester while the system is hot. Allow components to cool sufficiently before proceeding. Use the following procedure to periodically purge accumulated carbon 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 press and release the throttle pedal several times to purge carbon from the system. 5. If carbon comes out of the Clean-Out exhaust, cover or plug the Exhaust Outlet Plug exhaust outlet. Wear protective gloves. 6. Lightly tap on the exhaust pipe with a rubber mallet while repeating step 4. 7. If particles are still suspected to be in the muffler, elevate the rear of the vehicle one foot (30 cm) higher than the front. Block the wheels. 8. Place the transmission in PARK. Repeat steps 4 to 6 until no more particles are expelled. 9. Stop the engine. Allow the arrester to cool. 10. Reinstall the arrester plug and remove the exhaust outlet cover or plug. 108 MAINTENANCE Throttle System WARNING Failure to check or maintain proper operation of the throttle system can result in an accident and lead to serious injury or death if the throttle pedal sticks during operation. Never start or operate this vehicle if it has a sticking or improperly operating throttle pedal. Immediately contact your POLARIS dealer or other qualified person for service if throttle problems arise. Always check the pedal for free movement and return before starting the engine and occasionally during operation. Throttle Freeplay If the throttle pedal has excessive play due to cable stretch or misadjustment, it will cause a delay in throttle response, especially at low engine speed. The throttle may also not open fully. If the throttle pedal has no freeplay, the throttle may be hard to control, and the idle speed may be erratic. Check the throttle pedal freeplay at the intervals outlined in the Periodic Maintenance Chart beginning on page 81. Adjust the freeplay if necessary. Throttle Pedal Throttle Freeplay Inspection 1. Place the transmission in PARK. 2. Apply the brakes. Start the engine. Allow it to warm up thoroughly. 3. Measure the distance the throttle pedal moves before the engine begins to pick up speed. Freeplay should be 1/16 to 1/8 inches (1.53 mm). 4. Adjust freeplay as needed. See page 110. 109 MAINTENANCE Throttle System Throttle Pedal Freeplay Adjustment NOTICE: Engine idle speed is established at the factory and is not adjustable. Never attempt to adjust engine idle speed by adjusting throttle pedal freeplay. At operating temperature, idle speed should be 1250 +/- 50 RPM. If engine idle speed is not satisfactory, please see your POLARIS dealer or other qualified service person. 1. Place the transmission in PARK. 2. Apply the brakes. Start the engine. Allow it to warm up thoroughly. 3. Measure the distance the throttle pedal moves before the engine begins to pick up speed. Freeplay should be 1/16 to 1/8 inches (1.53 mm). 4. Remove the seat. Remove the engine access panel. See page 28. 5. Locate the in-line throttle cable adjuster near the engine valve cover. 6. Slide the cable adjuster boot off the cable adjuster. Throttle Cable Adjuster 7. Loosen the adjustment jam nut. 8. Rotate the cable adjuster until 1/16” to 1/8” (1.5-3 mm) of freeplay is achieved at the throttle pedal. See page 109. While adjusting, lightly flip the throttle pedal up and down. 9. Tighten the jam nut. 10. Apply a small amount of grease to the inside of the boot and slide it over the cable adjuster to its original position. 110 MAINTENANCE Brakes The front and rear brakes are hydraulic disc type brakes activated by the brake pedal. See page 33. Always check brake pedal travel and the brake fluid reservoir level before each use of the vehicle. When applied, the brake pedal should feel firm. Any sponginess would indicate a possible fluid leak or low brake fluid level, which must be corrected before riding. See page 112 for brake fluid information. If you discover any irregularities in brake system operation, including excessive pedal travel, contact your POLARIS dealer for proper diagnosis and repairs. WARNING! Operating the vehicle with a spongy brake pedal can result in loss of braking, which could cause an accident resulting in severe injury or death. Never operate the vehicle with a spongy-feeling brake pedal. 111 MAINTENANCE Brakes Brake Fluid Inspect the level of the brake fluid before each operation. If the fluid level is low add DOT 4 brake fluid only. See page 134 for the part numbers of POLARIS products. WARNING! After opening a bottle of brake fluid, always discard any unused portion. Never store or use a partial bottle. Brake fluid is hygroscopic, meaning it rapidly absorbs moisture from the air. The moisture causes the boiling temperature of the brake fluid to drop, which can lead to early brake fade and the possibility of accident or severe injury. Change the brake fluid every two years and any time the fluid becomes contaminated, the fluid level is below the minimum, or if the type and brand of the fluid in the reservoir are unknown. 1. Position the vehicle on a level surface. 2. Place the transmission in PARK. 3. Remove the front box cover and access panel. See page 26. 4. View the brake fluid level in the reservoir. The level should be between the maximum and minimum level lines. 5. If the fluid level is lower than the lower level line, add brake fluid to the upper line. 6. Apply the brake forcefully for a few seconds and check for fluid leakage around the fittings. 112 Brake Fluid Reservoir Minimum Brake Fluid Reservoir Maximum MAINTENANCE Brakes Brake Inspection 1. Check the brake system for fluid leaks. 2. Check the brake pedal for excessive travel or a spongy feel. 3. Check the friction pads for wear, damage and looseness. 4. Check brake discs for signs of cracks, excessive corrosion, warping or other damage. Clean any grease using an approved brake cleaner or alcohol. 0.030" (0.762mm) WARNING! Do not apply WD-40 or any petroleum product to brake discs. These types of products are flammable and may also reduce the friction between the brake pad and caliper. 5. Inspect the brake disc spline and pad wear surface for excessive wear. Change pads when worn to 0.030” (0.762 mm). 113 MAINTENANCE Steering Wheel Inspection Check the steering wheel for specified freeplay and smooth operation at the intervals outlined in the Periodic Maintenance Chart beginning on page 81. 1. Position the vehicle on level ground. 2. Lightly turn the steering wheel left and right. 3. There should be 0.8”-1.0” (20-25 mm) of freeplay. 4. If there is excessive freeplay or strange noises, or the steering feels rough or “catchy,” have the steering system inspected by an authorized POLARIS dealer. Rear Spring The rear shock absorber spring is adjusted by rotating the adjuster either clockwise or counter-clockwise to increase or decrease spring tension. Accessory springs are available through your POLARIS dealer. 114 Adjuster MAINTENANCE Tires WARNING Operating your vehicle with worn tires will increase the possibility of skidding, loss of control and an accident, which could result in serious injury or death. Always replace tires when the tread depth measures 1/8” (3 mm) or less. Improper tire inflation or the use of non-standard size or type of tires may adversely affect vehicle handling, which could result in vehicle damage or personal injury. Always maintain proper tire pressure. Always use POLARISapproved size and type of tires for this vehicle when replacing tires. Tire Tread Depth Always replace tires when tread depth is worn to 1/8” (3 mm) or less. 1/8" (3 mm) Axle and Wheel Nut Torque Specifications Inspect the following items occasionally for tightness, and if they've been loosened for maintenance service. Do not lubricate the stud or the lug nut. Lug Nut (Aluminum Wheels) Front and Rear 30 ft. lbs. (41 Nm) PLUS 1/4 TURN or 90 degrees 2-Piece Flange Nut (Steel Wheels) Front and Rear 27 ft. lbs. (37 Nm) Hub Retaining Nut Front and Rear 80 ft. lbs. (108 Nm) 115 MAINTENANCE Tires Wheel Removal 1. 2. 3. 4. Position the vehicle on a level surface. Place the transmission in PARK. Stop the engine. Loosen the wheel nuts slightly. Elevate the side of the vehicle by placing a suitable stand under the frame. 5. Remove the wheel nuts and washers. Remove the wheel. Wheel Installation 1. Place the transmission in PARK. 2. Place the wheel on the hub with the valve stem toward the outside and rotation arrows on the tire pointing toward forward rotation. WARNING! Improperly installed wheels can adversely affect tire wear and vehicle handling, which can result in serious injury or death. Always ensure that all nuts are torqued to specification. Do not service axle nuts that have a cotter pin installed. Your POLARIS dealer can assist. 3. Attach the wheel nuts and washers and finger-tighten. 4. Carefully lower the vehicle to the ground. 5. Torque the wheel nuts to specification. See page 115. 116 MAINTENANCE Lights Headlight and taillight lenses become dirty during normal operation. Clean all lights frequently to ensure a clear field of vision as well as visibility to other vehicles. When servicing a halogen lamp, don't touch the lamp with bare fingers. Oil from your skin leaves a residue, causing a hot spot that will shorten the life of the lamp. LED Headlamps (if equipped) If a headlight becomes damaged or inoperable, the entire headlight assembly must be replaced. Tip: If an LED headlamp has moisture or fogging inside, disconnect the wiring harness from the headlamp(s) for a few days to allow the moisture to clear out. Do not operate the vehicle at night or in low light conditions without properly working headlights. Headlight Lamp Replacement Do not service the headlamps until they've cooled sufficiently. 1. Unplug the headlamp from the wiring harness. Be sure to pull on the connector, not on the wiring. 2. Turn the lamp counterclockwise to remove it. 3. Install the new lamp. Make sure the tab on the lamp locates properly in the Wiring Harness housing. 4. Reinstall the harness assembly into the headlight assembly. 117 MAINTENANCE Lights Headlight Beam Adjustment X 25 ft. (7.6 m) X 8" (20 cm) 1. Place the vehicle on a level surface with the headlight approximately 25 ft. (7.6 m) from a wall. 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 height. 3. Apply the brakes. Turn the ignition switch to the LIGHTS ON position. 4. Observe the headlight aim. The most intense part of the headlight beam should be aimed 8" (20 cm) below the mark placed on the wall in step 2. Include the weight of a rider on the seat while performing this step. 5. If adjustment is necessary, turn the headlight adjustment screw to adjust the beam. Adjustment 6. Repeat steps 4-5 until the beam is Screw properly adjusted. 118 MAINTENANCE Lights Brake Lights When the brake pedal is depressed, the brake light comes on. Check the brake light before each ride. 1. Turn the ignition switch to the LIGHTS ON position. 2. Apply the brakes. The brake light should come on after about 10 mm (0.4 in.) of pedal travel. If the light doesn't come on, check the bulb. Vehicle Immersion NOTICE: If your vehicle becomes immersed, major engine damage can result if the machine is not thoroughly inspected. Take the vehicle in for service before starting the engine. Your POLARIS dealer can provide this service. If it's impossible to take your vehicle to a dealer before starting it, follow the steps outlined below. 1. Move the vehicle to dry land. 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. 5. Dry the spark plug and reinstall it, or install a new plug. 6. Attempt to start the engine. If necessary, repeat the drying procedure. 7. Take the vehicle in for service as soon as possible, whether you succeed in starting it or not. Your POLARIS dealer can provide the required service. 8. If water has been ingested into the PVT follow the procedure on page 105 for drying. 119 MAINTENANCE Battery WARNING Battery electrolyte is poisonous. It contains sulfuric acid. Serious burns can result from contact with skin, eyes or clothing. Antidote: External: Flush with water. Internal: Drink large quantities of water or milk. Follow with milk of magnesia, beaten egg, or vegetable oil. Call physician immediately. Eyes: Flush with water for 15 minutes and get prompt medical attention. Batteries produce explosive gases. Keep 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 the top of the battery. Always keep battery terminals and connections free of corrosion. If cleaning is necessary, remove the corrosion with a stiff wire brush. Wash with a solution of one tablespoon baking soda and one cup water. Rinse well with tap water and dry off with clean shop towels. Coat the terminals with dielectric grease or petroleum jelly. Be careful not to allow cleaning solution or tap water into a conventional battery. 120 MAINTENANCE Battery WARNING Improperly connecting or disconnecting battery cables can result in an explosion and cause serious injury or death. When removing the battery, always disconnect the negative (black) cable first. When reinstalling the battery, always connect the negative (black) cable last. Battery Removal 1. Remove the seat. See page 28. 2. Remove the three (3) bolts securing the cup holder panel to the frame. Lift the panel to access the battery. 3. Remove the battery hold-down strap screws and remove the strap. 4. On conventional batteries, remove the battery vent tube. 5. Disconnect the black (negative) battery cable first. 6. Disconnect the red (positive) battery cable last. 7. Lift the battery out of the vehicle. Be careful not to tip a conventional battery sideways, which could spill electrolyte. NOTICE: If electrolyte spills, immediately wash it off with a solution of one tablespoon baking soda and one cup water to prevent damage to the vehicle. Cup Holder Panel Bolts Battery Hold-Down Strap Battery 121 MAINTENANCE Battery Battery Installation Using a new battery that has not been fully charged can damage the battery and result in a shorter life. It can also hinder vehicle performance. Follow the battery charging instructions on page 124 before installing the battery. An optional extreme use battery may be available for your model. If the performance of the factory-installed battery is inadequate due to operation in extreme cold or due to extended use of multiple electrical accessories, , your POLARIS dealer can assist. Your dealer can provide any installation procedures that may differ for an extreme use battery. 1. Ensure that the battery is fully charged. 2. Place the battery in the battery holder. 3. On 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 tube away from the frame and vehicle body to prevent contact with electrolyte. WARNING! Battery gases could accumulate in an improperly installed vent tube and cause an explosion, resulting in serious injury or death. Always ensure that the vent tube is free of obstructions and is securely installed as recommended. 4. 5. 6. 7. 8. 9. 10. 122 Coat the terminals with dielectric grease or petroleum jelly. Connect and tighten the red (positive) cable first. Connect and tighten the black (negative) cable last. Install the battery hold-down strap and tighten the screws. Verify that cables are properly routed. Reinstall the cup holder panel. Tighten the bolts. Reinstall the seat. MAINTENANCE Battery 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. See page 124. Tip: Battery charge can be maintained by using a POLARIS Battery Tender charger or by charging about once a month to make up for normal selfdischarge. Battery Tender can be left connected during the storage period, and will automatically charge the battery if the voltage drops below a predetermined point. See page 134 for the part numbers of POLARIS products. Battery Fluid (Conventional Battery) A poorly maintained battery will deteriorate rapidly. Check the battery fluid level often. Maintain the fluid level between the upper and lower level marks. Add only distilled water. Tap water contains minerals that are harmful to a battery. Lower Mark Upper Mark 123 MAINTENANCE Battery Battery Charging (Conventional Battery) 1. Remove the battery from the vehicle to prevent damage from leaking or spilled electrolyte during charging. See page 121. 2. Charge the battery with a charging output no larger than 1/10 of the battery’s amp/hr rating. Charge as needed to raise the specific gravity to 1.270 or greater. 3. Reinstall the battery. See page 122. Make sure the positive terminal is toward the front of the vehicle. Battery Charging (Sealed Battery) 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 maintaining a sealed battery is to keep it fully charged. Since the battery is sealed and the sealing strip cannot be removed, you must use a voltmeter or multimeter to measure DC voltage. WARNING! An overheated battery may explode, causing severe injury or death. Always watch charging times carefully. Stop charging if the battery becomes very warm to the touch. Allow it to cool before resuming charging. For a refresh charge, follow all instructions carefully. 1. Check the battery voltage with a voltmeter or multimeter. A fully charged battery will register 12.8 V or higher. 2. If the voltage is less than 12.8 volts, recharge the battery at 1.2 amps or less until battery voltage is 12.8 or greater. Tip: When using an automatic charger, refer to the charger manufacturer's instructions for recharging. When using a constant current charger, use the guidelines on the next page for recharging. 124 MAINTENANCE Battery Battery Charging (Sealed Battery) Always verify battery condition before and 1-2 hours after the end of charging. Charge Time State of Charge Voltage Action (Using constant current charger @ standard amps specified on top of battery) 100% 12.8-13.0 volts None required 75%-100% 12.5-12.8 volts 50%-75% 25%-50% 12.0-12.5 volts 11.5-12.0 volts None, check at 3 mos. from date of manufacture May need slight charge, if no charge given, check in 3 months Needs charge Needs charge 0%-25% 11.5 volts or less Needs charge with desulfating charger 3-6 hours 5-11 hours At least 13 hours, verify state of charge At least 20 hours 125 MAINTENANCE Cleaning and Storage Washing the Vehicle Keeping your POLARIS vehicle clean will not only improve its appearance but it can also extend the life of various components. PVT Intake Pre-Filter NOTICE: Water in the PVT system could cause the drive belt to become wet and slip in the clutches. Always avoid spraying water directly toward any intake pre-filters. High water pressure may damage the radiator fins and impair the radiator’s effectiveness. High pressure may also damage other vehicle components. Certain products, including insect repellents and chemicals, will damage plastic surfaces. Do not allow these types of products to contact the vehicle. The best and safest way to clean your POLARIS vehicle is with a garden hose and a pail of mild soap and water. 1. Use a professional-type washing cloth, cleaning the upper body first and the lower parts 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 will scratch the finish. 126 MAINTENANCE Cleaning and Storage Washing the Vehicle If a high pressure water system is used for cleaning (not recommended), exercise extreme caution. The water may damage components and could remove paint and labels. Avoid directing the water stream at the following items: • Wheel bearings • Radiator • Transmission seals • Brakes • Cab and body panels • Labels and decals • Electrical components and wiring • Air intake components If warning and safety labels are damaged, contact your POLARIS dealer for free replacement. Grease all zerk fittings immediately after washing. Allow the engine to run for a while to evaporate any water that may have entered the engine or exhaust system. Polishing the Vehicle POLARIS recommends the use of common household aerosol furniture polish for polishing the finish on your POLARIS vehicle. Follow the instructions on the container. Polishing Tips • Avoid the use of automotive products, some of which can scratch the finish of your vehicle. • Always use clean cloths and pads for cleaning and polishing. Old or reused cloths and pads may contain dirt particles that will scratch the finish. 127 MAINTENANCE Cleaning and Storage Chrome Wheel Care (if equipped) Proper maintenance will protect chrome wheels from corrosion, preserve wheel life and ensure a “like new” appearance for many years. Tip: 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. 2. Rinse well with clear water. Soap, detergents, salt, dirt, mud and other elements can cause corrosion. 3. Polish the clean chrome wheels periodically. Use an automotive grade chrome polish. 4. Routinely and liberally apply a weather resistant wax to each polished chrome wheel. Choose a product suitable for chrome finishes. Read and follow the product labels and instructions. Removing Corrosion If light rust is found on the chrome finish, use steel wool (#0000-OTT grade) to remove it. Gently rub the affected areas with the steel wool until the corrosion has been removed. Clean and polish the wheel as outlined above. 128 MAINTENANCE Cleaning and Storage Storage Tips NOTICE: Starting the engine during the storage period will disturb the protective film created by fogging and damage could occur. Never start the engine during the storage period. Clean the Exterior Make any necessary repairs and clean the vehicle as recommended. See page 126. Stabilize the Fuel 1. Fill the fuel tank. 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 removes water from fuel systems, 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 page 90 (325) or page 92 (570). Air Filter / Air Box Inspect and clean or replace the pre-filter and air filter. Clean the air box. See page 106. Fluid Levels Inspect the fluid levels. Add or change fluids as recommended in the Periodic Maintenance Chart beginning on page 81. • Demand drive fluid (front gearcase) • Rear gearcase fluid (if equipped) • Transmission fluid • Brake fluid (change every two years and any time the fluid looks dark or contaminated) • Coolant (test strength/fill) 129 MAINTENANCE Cleaning and Storage Storage Tips Inspect and Lubricate Inspect all cables and lubricate all areas of the vehicle as recommended in the Periodic Maintenance Chart beginning on page 81. Fog the Engine 1. Treat the fuel system with POLARIS Carbon Clean or other equivalent fuel treatment. Follow the instructions on the container. Start the engine. Allow it to idle for several minutes so the Carbon Clean reaches the injectors. Stop the engine. 2. Remove the spark plug and add 2-3 tablespoons of engine oil. To access the plug holes, use a section of clear 1/4” hose and a small plastic squeeze bottle filled with the pre-measured amount of oil. Do this carefully! If you miss the plug holes, oil will drain 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 plug. Torque to specification. See page 97. 4. Apply dielectric grease to the inside of each spark plug cap. Do not reinstall the cap onto the plug at this step. 5. Turn the engine over several times. Oil will be forced in and around the piston rings and ring lands, coating the cylinder with a protective film of fresh oil. 6. If POLARIS fuel system additive is not used, fuel tank, fuel lines, and injectors should be completely drained of gasoline. 7. Reinstall the spark plug cap to the spark plug. Battery Maintenance See pages 123-125 for storage and charging procedures. Storage Area/Covers Be sure the storage area is well ventilated. Cover the vehicle with a genuine POLARIS cover. Do not use plastic or coated materials. They do not allow enough ventilation to prevent condensation, and may promote corrosion and oxidation. 130 MAINTENANCE Cleaning and Storage Removal from Storage 1. Check the battery electrolyte level and charge the battery if necessary. Install it in the vehicle. Make sure the battery vent hose is routed properly and that it's not pinched or restricted in any way. 2. Make sure the spark plug is tight. 3. Fill the fuel tank with fuel. 4. Check all the points listed in the Daily Pre-Ride Inspection section on page 51. Tightness of the bolts, nuts and other fasteners should be checked by an authorized POLARIS dealer or other qualified service facility. 5. Lubricate at the intervals outlined in the Periodic Maintenance Chart beginning on page 81. WARNING! Engine exhaust contains poisonous carbon monoxide and can cause loss of consciousness or death. Never run an engine in an enclosed area. Transporting the Vehicle Follow these procedures when transporting the vehicle. 1. Place the transmission in PARK. Stop the engine. 2. Remove the key to prevent loss during transporting. 3. Secure the fuel cap and seat. Ensure that the seat is attached correctly and is not loose. WARNING! Cargo and other loose vehicle parts may fly off while transporting this vehicle. Secure or remove all cargo, and inspect the unit for loose parts prior to transport. 4. Always tie the frame of the POLARIS vehicle to the transporting unit securely with suitable straps or rope. Do not attach tie straps to the front control arm bolt pockets. 131 SPECIFICATIONS ACE / ACE 570 Gross Vehicle Weight Dry Weight Test GVW - Rollover Protection System (ROPS) Front Rack/Box Capacity Rear Rack/Box Capacity Maximum Weight Capacity (Payload) Receiver Hitch Tongue Capacity Receiver Hitch Towing Capacity Fuel Capacity Engine Oil Capacity Coolant System Capacity Coolant Bottle Capacity Demand Drive Fluid Capacity Transmission Oil Capacity Overall Length/Width/Height Wheelbase Ground Clearance Engine Displacement Bore x Stroke Alternator Output Compression Ratio Starting System Fuel System Throttle Body Size Ignition System Ignition Timing Spark Plug / Gap Front Suspension Rear Suspension 132 1455 lbs. (660 kg) 835 lbs. (378.7 kg) (325) 865 lbs. (392.4 kg) (+/- 5%) (570) 1505 lbs. (682.7 kg) per OSHA 29 CFR 1928.53 120 lbs. (54 kg) 240 lbs. (108 kg) 575 lbs. (260 kg) (operator/cargo/accessories/ trailer tongue weight) 150 lbs. (68 kg) 1500 lbs. (680 kg 5.25 gal. (19.9 l) 1.75 qts. (1.65 l) (325) 2 qts. (1.9 l) (570) 86 oz. (2.5 l) (325) excluding coolant bottle 96 oz. (2.8 l) (570) excluding coolant bottle 8 oz. (237 ml) 9 oz. (265 ml) 44 oz. (1300 ml) 90/48/68 in. (228.6/122/173 cm) 61.5 in. (156.2 cm) 10.25 in. (26 cm) Dual overhead cam, 4 valve 4 stroke single cylinder 325 cc (325) / 567 cc (570) 78 mm x 68 mm (325) 99 mm x 73.6 mm (570) 560 W @ 7000 RPM 11.5:1 (325) / 10:1 (570) Electric Electronic fuel injection 36 mm (325) / 42 mm (570) Digital CDI 32° +/- 2° @ 5000 RPM (325) 10° +/- 1° @ 1200 RPM (570) (non-adjustable) NGK MR7F / 0.8 +/- 0.1 mm MacPherson strut with 8.2 in. (20.8 cm) travel Dual A-arm, anti-sway bar with 9.5 in. (24.1 cm) travel SPECIFICATIONS ACE / ACE 570 Lubrication System Engine Oil Driving System Type Shift Type Gear Reduction - Low Gear Reduction - Reverse Gear Reduction - High Drive Ratio - Front Tire Size - Front Tire Size - Rear Tire Pressure Brakes, Park Brakes, Front/Rear Headlights Taillights Brake Lights Instrument Cluster Auxiliary DC Outlet Wet Sump PS-4 5W-50 Automatic POLARIS Variable Transmission Side Lever (H/L/N/R/P) 28.84:1 25.83:1 9.65:1 2.989:1 25x8-12 25x10-12 Front: 7 psi (48 KPa) Rear: 7 psi (48 KPa) Park in Transmission Foot Activated, 4-wheel hydraulic disc 2 single beam, 55W halogen 2 single beam, 6W 2 single beam, 27W LCD 12V Clutching (325) Please see your dealer for clutching specifications. Clutching (570) Altitude Meters (Feet) Shift Weight Drive Clutch Spring Driven Clutch Spring 0-1500 (0-5000) 25-52 PN 5632409 Black 35-240 PN 7043594 Black/Almond PN 3235088 1500-3700 (5000-12000) 25-48 PN 5632408 Black 35-240 PN 7043594 Black/Almond PN 3235088 133 POLARIS PRODUCTS Part Number 2870791 2876244 2876245 2878068 2878069 2870465 2877922 2877923 2880514 2880513 2871312 2871322 2871423 2871460 2871515 2871551 2871329 2871326 2870652 2872189 2871956 2859044 134 Description Engine Lubricant Fogging Oil (12 oz./355 ml Aerosol) PS-4 Full Synthetic 5W-50 4-Cycle Oil (qt./.95 l) PS-4 Full Synthetic 5W-50 4-Cycle Oil (gal./3.8 l) Gearcase / Transmission Lubricants AGL Full Synthetic Gearcase Lubricant & Transmission Fluid (qt./.95 l) AGL Full Synthetic Gearcase Lubricant & Transmission Fluid (gal./3.8 l) Pump for Gallon (3.8 l) Jug Demand Drive Fluid (qt./.95 l) Demand Drive Fluid (gal./3.8 l) Coolant Antifreeze 50/50 Premix (qt./.95 l) Antifreeze 50/50 Premix (gal./3.8 l) Grease / Specialized Lubricants Grease Gun Kit, Premium All Season All Season Grease (3 oz./89 ml cartridge) All Season Grease (14 oz./414 ml cartridge) Premium Starter Grease U-Joint Grease (3 oz./89 ml cartridge) U-Joint Grease (14 oz./414 ml cartridge) Dielectric Grease (Nyogel™) Additives / Miscellaneous Carbon Clean Fuel Stabilizer DOT 4 Brake Fluid Loctite™ 565 Thread Sealant POLARIS Battery Tender™ Charger TROUBLESHOOTING Drive Belt Wear/Burn Possible Cause Driving onto a pickup or tall trailer in high range Starting out going up a steep incline Driving at low RPM or ground speed (3-7 MPH) Insufficient warm-up at low ambient temperatures Slow/easy clutch engagement Towing/pushing at low RPM/low ground speed Utility use/plowing Stuck in mud or snow Climbing over large objects from a stopped position Belt slippage from water or snow ingestion into the PVT system Clutch malfunction Poor engine performance Slippage from failure to warm up belt Wrong or missing belt Improper break-in Solution Use low range during loading. Use low range. See warnings on page 60. Drive at a higher speed or use low range more frequently. Warm the engine at least 5 minutes. With the transmission in neutral, advance the throttle to about 1/8 throttle in short bursts, 5 to 7 times. The belt will become more flexible and prevent belt burning. Use the throttle quickly and effectively. Use low range only. Use low range only. Shift the transmission to low range and carefully use fast, aggressive throttle application to engage clutch. WARNING: Excessive throttle may cause loss of control and vehicle rollover. Shift the transmission to low range and carefully use fast, brief, aggressive throttle application to engage clutch. WARNING: Excessive throttle may cause loss of control and vehicle rollover. Dry out the PVT (see page 105). Prevent water from entering the PVT intake duct (see page 107). Inspect clutch seals for damage if repeated leaking occurs. Your POLARIS dealer can assist. Check for fouled plug or foreign material in gas tank or fuel lines. Your POLARIS dealer can assist. Always warm up the belt by operating below 30 mph for one mile (5 miles or more when temperature is below freezing). Install the recommended belt. Always break in a new belt and/or clutch. See page 49. 135 TROUBLESHOOTING Engine Doesn't Turn Over Possible Cause Low battery voltage Loose battery connections Loose solenoid connections Loose electronic control box connections Solution Recharge the battery to 12.8 VDC Check all connections and tighten Check all connections and tighten Inspect, clean, reinstall connectors Engine Turns Over, Fails to Start Possible Cause Out of fuel Clogged fuel filter Water is present in fuel Old or non-recommended fuel Fouled or defective spark plug No spark to spark plug Water or fuel in crankcase Low battery voltage Mechanical failure Solution Refuel Your POLARIS dealer can assist. Drain the fuel system and refuel Replace with fresh recommended fuel Inspect plug and replace if necessary Inspect plug and replace if necessary Your POLARIS dealer can assist. Recharge the battery to 12.8 VDC Your POLARIS dealer can assist. Engine Backfires Possible Cause Weak spark from spark plug Incorrect spark plug gap or heat range Old or non-recommended fuel Incorrectly installed spark plug wires Incorrect ignition timing Mechanical failure Loose ignition connections Water present in fuel 136 Solution Inspect, clean and/or replace spark plug Set gap to specs or replace plug Replace with fresh recommended fuel Your POLARIS dealer can assist. Your POLARIS dealer can assist. Your POLARIS dealer can assist. Check all connections and tighten Replace with fresh recommended fuel TROUBLESHOOTING Engine Pings or Knocks Possible Cause Poor quality or low octane fuel Incorrect ignition timing Incorrect spark plug gap or heat range Solution Replace with recommended fuel Your POLARIS dealer can assist. Set gap to specs or replace plug Engine Runs Irregularly, Stalls or Misfires Possible Cause Fouled or defective spark plug Worn or defective spark plug wires Incorrect spark plug gap or heat range Loose ignition connections Water present in fuel Low battery voltage Kinked or plugged fuel tank vent line Incorrect fuel Clogged air filter Low fuel pressure Other mechanical failure Possible Lean Fuel Cause Low or contaminated fuel Low octane fuel Clogged fuel filter Possible Rich Fuel Cause Fuel is very high octane Solution Inspect, clean and/or replace spark plug Your POLARIS dealer can assist. Set gap to specs or replace plug Check all connections and tighten Replace with new fuel Recharge battery to 12.8 VDC Inspect and replace Replace with recommended fuel Inspect and clean or replace Your POLARIS dealer can assist. Your POLARIS dealer can assist. Solution Add or change fuel, clean the fuel system Replace with recommended fuel Your POLARIS dealer can assist. Solution Replace with lower octane fuel 137 TROUBLESHOOTING Engine Stops or Loses Power Possible Cause Out of fuel Kinked or plugged fuel vent line Water is present in fuel Fouled or defective spark plug Worn or defective spark plug wires Incorrect spark plug gap or heat range Loose ignition connections Low battery voltage Incorrect fuel Clogged air filter Other mechanical failure Overheated engine 138 Solution Refuel Inspect and replace Replace with new fuel Inspect, clean and/or replace spark plug Your POLARIS dealer can assist. Set gap to specs or replace plug Check all connections and tighten Recharge the battery to 12.8 VDC Replace with fresh recommended fuel Inspect and clean or replace Your POLARIS dealer can assist. Clean radiator screen and core, clean engine exterior. Your POLARIS dealer can assist. WARRANTY Limited Warranty POLARIS Industries Inc., 2100 Highway 55, Medina, MN 55340 (POLARIS) gives a SIX MONTH 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. Warranty Coverage And Exclusions: Limitations Of Warranties And Remedies This POLARIS limited warranty excludes any failures that are not caused by a defect in material or workmanship. THIS WARRANTY DOES NOT COVER CLAIMS OF DEFECTIVE DESIGN. This warranty also does not cover acts of God, accidental damage, normal wear and tear, abuse or improper handling. This warranty also does not cover any vehicle, component, or part that has been altered structurally, modified, neglected, improperly maintained or used for racing, competition or purposes other than for which it was designed. This warranty excludes damages or failures resulting from improper lubrication; improper engine timing; improper fuel; surface imperfections caused by external stress, heat, cold or contamination; operator error or abuse; improper component alignment, tension, adjustment or altitude compensation; snow, water, dirt or other foreign substance ingestion/contamination; improper maintenance; modified components; use of aftermarket or unapproved components, accessories, or attachments; unauthorized repairs; or repairs made after the warranty period expires or by an unauthorized repair center. 139 WARRANTY Warranty Coverage And Exclusions: Limitations Of Warranties And Remedies This warranty excludes damages or failures caused by abuse, accident, fire, or any other cause other than a defect in materials or workmanship and provides no coverage for consumable components, general wear items, or any 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: • • • • • • • • • • • Wheels and tires Suspension components Brake components Seat components Clutches and components Steering components Batteries Light bulbs/Sealed beam lamps Filters Lubricants Bushings • • • • • • • • • • • Finished and unfinished surfaces Carburetor/Throttle body components Engine components Drive belts Hydraulic components and fluids Circuit breakers/Fuses Electronic components Spark plugs Sealants Coolants Bearings Lubricants and Fluids 1. Mixing oil brands or using non-recommended oil may cause engine damage. We recommend the use of POLARIS engine oil. 2. Damage or failure resulting from the use of non-recommended lubricants or fluids is not covered by this warranty. This warranty provides no coverage for personal loss or expense, including mileage, transportation costs, hotels, meals, shipping or handling fees, product pick-up or delivery, replacement rentals, loss of product use, loss of profits, or loss of vacation or personal time. THE EXCLUSIVE REMEDY FOR BREACH OF THIS WARRANTY SHALL BE, AT POLARIS' OPTION, REPAIR OR REPLACEMENT OF ANY DEFECTIVE MATERIALS, COMPONENTS, OR PRODUCTS. THE REMEDIES SET FORTH IN THIS WARRANTY ARE THE ONLY REMEDIES AVAILABLE TO ANY PERSON FOR BREACH OF THIS WARRANTY. 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, OR OTHER TORT OR OTHERWISE. THIS EXCLUSION OF CONSEQUENTAL, 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 FITNESS FOR A PARTICULAR PURPOSE IS EXCLUDED FROM THIS LIMITED WARRANTY. ALL OTHER IMPLIED WARRANTIES (INCLUDING BUT NOT LIMITED TO THE IMPLIED WARRANTY OF MERCHANTABILITY) ARE LIMITED IN DURATION TO THE ABOVE SIX MONTH WARRANTY PERIOD. POLARIS DISCLAIMS ALL EXPRESS WARRANTIES NOT STATED IN THIS WARRANTY. SOME STATES DO NOT PERMIT THE EXCLUSION OR LIMITATION OF INCIDENTAL OR CONSEQUENTIAL DAMAGES OR ALLOW LIMITATIONS ON THE DURATION OF IMPLIED WARRANTIES, SO THE ABOVE LIMITATIONS MAY NOT APPLY TO YOU IF INCONSISTENT WITH CONTROLLING STATE LAW. 140 WARRANTY How To Obtain Warranty Service If your vehicle requires warranty service, you must take it to a POLARIS Servicing Dealer. When requesting warranty service you must present your copy of the Warranty Registration Form to the dealer. (THE COST OF TRANSPORTATION TO AND FROM THE DEALER IS YOUR RESPONSIBILITY.) POLARIS suggests that you use your original selling dealer; however, you may use any POLARIS Servicing Dealer to perform warranty service. In the Country where your product was purchased: Warranty or Service Bulletin repairs must be done by an authorized POLARIS dealer. If you move or are traveling within the country where your product was purchased, Warranty and Service Bulletin repairs may be requested from any authorized POLARIS dealer that sells the same line as your product. Outside the Country where your product was purchased: If you are traveling temporarily outside the country where your product was purchased, you should take your product to an authorized POLARIS dealer. You must show the dealer photo identification 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: 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 be required to present documentation of your move to POLARIS in order to continue your warranty coverage. You may also be required to obtain documentation from POLARIS in order to register your product in your new country. You should warranty register your product at a local POLARIS dealer in your new country immediately after you move to continue your warranty coverage and to ensure that you receive information and notices regarding your vehicle. If you purchase from a private party: If you purchase a POLARIS product from a private party, to be kept and used outside of the country in which the product was originally purchased, all warranty coverage will be denied. You must nonetheless register your product under your name and address with a local POLARIS dealer in your country to ensure that you receive safety information and notices regarding your product. Exported Products EXCEPT WHERE SPECIFICALLY REQUIRED BY LAW, THERE IS NO WARRANTY OR SERVICE BULLETIN COVERAGE ON THIS PRODUCT IF IT IS SOLD OUTSIDE THE COUNTRY OF THE SELLING DEALER'S AUTHORIZED LOCATION. This policy does not apply to products that have received authorization for export from POLARIS. Dealers may not give authorization for export. You should consult an authorized dealer to determine this product's warranty or service coverage if you have any questions. This policy does not apply to products registered to government officials or military personnel on assignment outside the country of the selling dealer's authorized location. This policy does not apply to Safety Bulletins. 141 WARRANTY Notice If your product is registered outside of the country where it was purchased and you have not 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 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. Should your dealer require any additional assistance, they will contact the appropriate person at POLARIS. This warranty gives you specific legal rights, and you may also have other rights which vary from state to state or in different countries. If any of the above terms are void because of federal, state, local law, all other warranty terms will remain in effect. For questions call POLARIS Customer Assistance: United States & Canada: 1-800-POLARIS (1-800-765-2747) French: 1-800-268-6334 142 WARRANTY U.S.A. EPA Emissions Limited Warranty This emissions limited warranty is in addition to the POLARIS standard limited warranty for your vehicle. POLARIS Industries Inc. warrants that at the time it is first purchased, this emissions-certified vehicle is designed, built and equipped so it conforms with applicable U.S. Environmental Protection Agency emission regulations. POLARIS warrants that the vehicle is free from defects in materials and workmanship that would cause it to fail to meet these regulations. The warranty period for off road vehicles 100cc or greater emissions-certified vehicles starts on the date of purchase by original retail purchaser and continues for a period of 500 hours of engine operation, 5000 kilometers (3100 miles) of vehicle travel, or 30 calendar months from the date of purchase, whichever comes first. The warranty period for ATVs less than 100cc emissions-certified vehicles starts on the date of purchase by original retail purchaser and continues for a period of 250 hours of engine operation, 2500 kilometers (1550 miles) of vehicle travel, or 30 calendar months from the 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 emissions warranty period does not further extend if you purchase additional warranty coverage in the form of a service contract or other paid warranty extension, but emission-related parts may be covered subject to the terms of any such paid service contract or paid warranty extension. This emissions limited warranty covers components whose failure increases the vehicle's regulated emissions, and it covers components of systems whose only purpose is to control emissions. Repairing or replacing other components not covered by this warranty is the responsibility of the vehicle owner. This emissions limited warranty does not cover components whose failure does not increase the vehicle's regulated emissions. For exhaust emissions, emission-related components include any engine parts related to the following systems: • Air-induction system • Fuel system • Ignition system • Exhaust gas recirculation systems The following parts are also considered emission-related components for exhaust emissions: • Aftertreatment devices • Crankcase ventilation valves • Sensors • Electronic control units 143 WARRANTY U.S.A. EPA Emissions Limited Warranty The following parts are considered emission-related components for evaporative emissions: • • • • • • • • • Fuel Tank Fuel Cap Fuel Line Fuel Line Fittings Clamps* Pressure Relief Valves* Control Valves* Control Solenoids* Electronic Controls* • • • • • • • • • Vacuum Control Diaphragms* Control Cables* Control Linkages* Purge Valves Vapor Hoses Liquid/Vapor Separator Carbon Canister Canister Mounting Brackets Carburetor Purge Port Connector *As related to the evaporative emission control system. Emission-related components also include any other part whose only purpose is to reduce emissions or whose failure will increase emissions without significantly degrading engine/equipment performance. The exclusive remedy for breach of this limited warranty shall be, at the exclusive option of POLARIS, repair or replacement of any defective materials, components or products. THE REMEDIES SET FORTH IN THIS LIMITED WARRANTY ARE THE ONLY REMEDIES AVAILABLE TO ANY PERSON FOR BREACH OF THIS WARRANTY. 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 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. ALL IMPLIED WARRANTIES (INCLUDING BUT NOT LIMITED TO ANY IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE) ARE LIMITED IN DURATION TO THE WARRANTY PERIOD DESCRIBED HEREIN. POLARIS DISCLAIMS ALL EXPRESS WARRANTIES NOT STATED IN THIS WARRANTY. Some states do not allow limitations on how long an implied warranty lasts, so the above limitation may not apply if it is inconsistent with the controlling state law. This limited warranty excludes failures not caused by a defect in material or workmanship. 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 that has been structurally altered, or when the vehicle has been used in racing competition. This limited warranty also does not cover physical damage, corrosion or defects caused by fire, explosions or other similar causes beyond the control of POLARIS. 144 WARRANTY U.S.A. EPA Emissions Limited Warranty Owners are responsible for performing the scheduled maintenance identified in the owner's manual. POLARIS may deny warranty claims for failures that have been caused by the owner's or operator's improper maintenance or use, by accidents for which POLARIS has no responsibility, or by acts of God. Any qualified repair shop or person may maintain, replace, or repair the emission control devices or systems on your vehicle. An authorized POLARIS dealer can perform any service that may be necessary for your vehicle. POLARIS also recommends POLARIS parts, however equivalent parts may be used for such service. It is a potential violation of the Clean Air Act if a part supplied by an aftermarket parts 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 available in 49-state and 50-state versions. Only the 50-state models are certified for sale in California. The 50-state models available for sale in California are identified by the letter “B” in the ninth position of the model number (e.g., R16RTE87B). The POLARIS 50-state models are designed and built with features such as a reduced cargo box capacity. Any modifications to these features may be a violation of the applicable California regulations and may void this limited emissions warranty offered by the manufacturer. If you have any questions regarding your warranty rights and responsibilities, please contact POLARIS Customer Assistance: United States & Canada: 1-800-POLARIS (1-800-765-2747) French: 1-800-268-6334 145 MAINTENANCE LOG Use the following chart to record periodic maintenance. DATE 146 MILES (KM) OR HOURS TECHNICIAN SERVICE PERFORMED / COMMENTS INDEX A C Access Panels . . . . . . . . . . . . . . . . . . 25 Accessory Outlet. . . . . . . . . . . . . . . . 31 Adding Coolant. . . . . . . . . . . . . . . . 100 Adjustment Seat. . . . . . . . . . . . . . . . . . . . . . . . 28 Steering Wheel . . . . . . . . . . . . . . . 26 Adjustment, Headlight Beam . . . . . 118 Adjustment, Throttle Freeplay . . . . 110 Age Restrictions . . . . . . . . . . . . . . . . 14 Air Filter . . . . . . . . . . . . . . . . . . . . . 106 Air Filter Cleaning . . . . . . . . . . . . . 106 All Wheel Drive Switch . . . . . . . . . . 31 All Wheel Drive System . . . . . . . . . . 35 Arrester Cleaning . . . . . . . . . . . . . . 108 Auxiliary Outlet . . . . . . . . . . . . . . . . 31 AWD Switch. . . . . . . . . . . . . . . . 31, 35 AWD System . . . . . . . . . . . . . . . . . . 35 Axle Nut Torque . . . . . . . . . . . . . . . 115 Cab Frame, ROPS. . . . . . . . . . . . . . . 34 Cab Nets . . . . . . . . . . . . . . . . . . . . . . 27 Cap, Fuel. . . . . . . . . . . . . . . . . . . . . . 28 Cargo. . . . . . . . . . . . . . . . . . . . . . 66-67 Changing Coolant . . . . . . . . . . . . . . 100 Changing Gears . . . . . . . . . . . . . . . . 32 Chart, Periodic Maintenance . . . 81-84 Check Engine Indicator . . . . . . . . . . 43 Chrome Wheel Care . . . . . . . . . . . . 128 Cleaning and Storage . . . . . . . 126-131 Cleaning the Air Filter . . . . . . . . . . 106 Clothing . . . . . . . . . . . . . . . . . . . . . . . 9 Clutching. . . . . . . . . . . . . . . . . . . . . 133 Component Locations . . . . . . . . . . . . 24 Condition, Spark Plugs . . . . . . . . . . . 97 Coolant Level . . . . . . . . . . . . . . . . . 102 Coolant Level, Radiator . . . . . . . . . 101 Coolant, Adding or Changing. . . . . 100 Cooling Fan . . . . . . . . . . . . . . . . . . 101 Cooling System. . . . . . . . . . . . 101-102 Cooling System Operation . . . . . . . 100 Corrosion Removal, Chrome . . . . . 128 Cover for Storage . . . . . . . . . . . . . . 130 Crankcase Emission Control System 80 B Battery . . . . . . . . . . . . . . . . . . 120-125 Charging. . . . . . . . . . . . . . . . . . . 124 Charging (Sealed Battery) . 124-125 Extreme Use . . . . . . . . . . . . . . . . . 27 Battery Fluid Replenishment . . . . . 123 Battery Installation . . . . . . . . . . . . . 122 Battery Removal . . . . . . . . . . . . . . . 121 Battery Storage . . . . . . . . . . . . . . . . 123 Before Riding . . . . . . . . . . . . . . . . . . 51 Belt Burning . . . . . . . . . . . . . . . . . . 135 Belt Life . . . . . . . . . . . . . . . . . . . . . . 67 Belt Replacement . . . . . . . . . . . . . . 104 Belt Wear . . . . . . . . . . . . . . . . . . . . 135 Belt, Seat . . . . . . . . . . . . . . . . . . . . . . 29 Boots . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Box Cover, Front . . . . . . . . . . . . . . . 26 Brake Fluid . . . . . . . . . . . . . . . . . . . 112 Brake Inspection . . . . . . . . . . . . . . . 113 Brake Lights . . . . . . . . . . . . . . . . . . 119 Brake Pedal . . . . . . . . . . . . . . . . . . . . 33 Brake System Break-in . . . . . . . . . . . 50 Brakes . . . . . . . . . . . . . . . . . . . 111-113 Braking . . . . . . . . . . . . . . . . . . . . . . . 55 Break-In Period. . . . . . . . . . . . . . 49-50 Breather Hose Inspection . . . . . . . . 107 Bumper Removal . . . . . . . . . . . . . . . 25 Burning Belts . . . . . . . . . . . . . . . . . 135 D Demand Drive Fluid . . . . . . . . . . . . . 94 Diagnostic Codes . . . . . . . . . . . . 44-48 Display Units, Standard/Metric . . . . 40 Drive Belt Wear . . . . . . . . . . . . . . . 135 Drivetrain Break-In. . . . . . . . . . . . . . 50 Driving Downhill . . . . . . . . . . . . . . . 62 Driving in Reverse . . . . . . . . . . . . . . 65 Driving on a Sidehill. . . . . . . . . . . . . 61 Driving on Slippery Surfaces . . . . . . 59 Driving Over Obstacles . . . . . . . . . . 64 Driving Procedures . . . . . . . . . . . 56-57 Driving Through Water . . . . . . . . . . 63 Driving Uphill. . . . . . . . . . . . . . . . . . 60 Driving, After Driving in Water . . . 105 Drying the Transmission. . . . . . . . . 105 E Electromagnetic Interference . . . . . . Electronic Power Steering . . . . . . . . Emission Control, Crankcase . . . . . . Emission Control, Exhaust . . . . . . . . 80 27 80 80 147 INDEX E F Emission Control, Noise . . . . . . . . . 80 Emissions Limited Warranty . . 143-145 Engaging AWD . . . . . . . . . . . . . . . . 35 Engine Break-In. . . . . . . . . . . . . . . . 50 Engine Fogging . . . . . . . . . . . . . . . 130 Engine Intake Pre-Filter. . . . . . . . . 107 Engine Oil . . . . . . . . . . . . . . . . . . 87-93 Engine Starting . . . . . . . . . . . . . . . . 54 Engine Stopping. . . . . . . . . . . . . . . . 55 Equipment Modifications . . . . . . . . 23 Error Codes, Engine. . . . . . . . . . . . . 43 Etiquette, Trail Riding . . . . . . . . . . . 53 Exhaust Emission Control System. . 80 Exhaust Pipe Cleaning. . . . . . . . . . 108 Extreme Use Battery . . . . . . . . . . . . 27 Eye Protection . . . . . . . . . . . . . . . . . . 9 Front Box Cover . . . . . . . . . . . . . . . . 26 Fuel Cap. . . . . . . . . . . . . . . . . . . . . . . 28 Fuel Safety. . . . . . . . . . . . . . . . . . . . . 22 Fuel Stabilizer . . . . . . . . . . . . . . . . . 129 Fuel Tank Filler Cap . . . . . . . . . . . . . 28 Fuse Box . . . . . . . . . . . . . . . . . . . . . . 99 Fuses . . . . . . . . . . . . . . . . . . . . . . 98-99 F Fan, Cooling . . . . . . . . . . . . . . . . . 101 Filling the Battery . . . . . . . . . . . . . 123 Filter Care During Storage. . . . . . . 129 Filter Cleaning, Air . . . . . . . . . . . . 106 Filter, Air . . . . . . . . . . . . . . . . . . . . 106 Fluid Demand Drive. . . . . . . . . . . . . . . 94 Front Gearcase . . . . . . . . . . . . . . 94 Main Gearcase . . . . . . . . . . . . . . 95 Transmission . . . . . . . . . . . . . . . . 95 Fluid Change Demand Drive. . . . . . . . . . . . . . . 94 Front Gearcase . . . . . . . . . . . . . . 94 Main Gearcase . . . . . . . . . . . . . . 95 Transmission . . . . . . . . . . . . . . . . 95 Fluid Check Coolant Bottle . . . . . . . . . . . . . . 102 Demand Drive. . . . . . . . . . . . . . . 94 Front Gearcase . . . . . . . . . . . . . . 94 Main Gearcase . . . . . . . . . . . . . . 95 Radiator Coolant . . . . . . . . . . . . 101 Transmission . . . . . . . . . . . . . . . . 95 Fluid Levels During Storage . . . . . 129 Fluid Recommendations, Gearcase . 96 Fluid, Battery . . . . . . . . . . . . . . . . . 123 Fluid, Brake . . . . . . . . . . . . . . . . . . 112 Fogging the Engine . . . . . . . . . . . . 130 Fouled Plugs . . . . . . . . . . . . . . . . . . 97 Freeplay Adjustment, Throttle. . . . 110 Freeplay, Steering Wheel. . . . . . . . 114 Freeplay, Throttle . . . . . . . . . . . . . 109 148 G Gap, Spark Plug. . . . . . . . . . . . . . . . . 96 Gasoline Handling . . . . . . . . . . . . . . . 22 Gear Selector . . . . . . . . . . . . . . . . . . . 32 Gearcase Capacities. . . . . . . . . . . . . . 96 Gearcase Oil Demand Drive. . . . . . . . . . . . . . . . 94 Front . . . . . . . . . . . . . . . . . . . . . . . 94 Main . . . . . . . . . . . . . . . . . . . . . . . 95 Gearcase Specifications. . . . . . . . . . . 96 Gearcases . . . . . . . . . . . . . . . . . . 94-96 Demand Drive. . . . . . . . . . . . . . . . 94 Front Gearcase . . . . . . . . . . . . . . . 94 Main Gearcase . . . . . . . . . . . . . . . 95 Specification Chart . . . . . . . . . . . . 96 Transmission. . . . . . . . . . . . . . . . . 95 Gears, shifting . . . . . . . . . . . . . . . . . . 32 Gloves . . . . . . . . . . . . . . . . . . . . . . . . . 9 H Hauling a Load . . . . . . . . . . . . . . 66-67 Hauling Cargo . . . . . . . . . . . . . . . 66-67 Headlight Beam Adjustment . . . . . . 118 Headlight Lamp Replacement . . . . . 117 Helmet . . . . . . . . . . . . . . . . . . . . . . . . . 8 Hitch . . . . . . . . . . . . . . . . . . . . . . . . . 25 Hitch Weight . . . . . . . . . . . . . . . . . . . 68 I Ignition Switch . . . . . . . . . . . . . . . . . 31 Indicator Lamps. . . . . . . . . . . . . . . . . 37 Inspection, Axle Nuts . . . . . . . . . . . 115 Inspection, Brakes . . . . . . . . . . . . . . 113 Inspection, Pre-Ride . . . . . . . . . . . . . 51 Inspection, Steering Wheel . . . . . . . 114 Inspection, Throttle Freeplay. . . . . . 109 Inspection, Wheel Nuts . . . . . . . . . . 115 Installation, Battery . . . . . . . . . . . . . 122 Installation, Wheels . . . . . . . . . . . . . 116 Instrument Cluster . . . . . . . . . . . . 36-48 Interference, Electromagnetic . . . . . . 80 INDEX K O Key, Periodic Maintenance Chart . . . 82 Oil Recommendations . . . . . . . . . . . 87 Operation on Public Lands . . . . . . . . 80 Operation, Cooling System. . . . . . . 100 Operation, Transmission. . . . . 103-105 Operator Restrictions . . . . . . . . . . . . 14 L Light Switch . . . . . . . . . . . . . . . . . . . 31 Lights . . . . . . . . . . . . . . . . . . . 117-119 Beam Adjustment. . . . . . . . . . . . 118 Brake Lights. . . . . . . . . . . . . . . . 119 Headlight Lamp Replacement . . 117 Loads, Towing . . . . . . . . . . . . . . . . . 68 Lubricant Part Numbers . . . . . . . . . 134 Lubrication for Storage . . . . . . . . . . 130 Lubrication Recommendations . . 85-86 M Maintenance Log . . . . . . . . . . . . . . 146 Maintenance, Periodic . . . . . . . . 81-84 Metric Display . . . . . . . . . . . . . . . . . 40 Mode Button . . . . . . . . . . . . . . . . . . . 36 Muffler Cleaning. . . . . . . . . . . . . . . 108 N Nets, Cab. . . . . . . . . . . . . . . . . . . . . . 27 New Operator Procedures . . . . . . 56-57 Noise Emission Control System . . . . 80 O Obstacles . . . . . . . . . . . . . . . . . . . . . . 64 Oil Demand Drive . . . . . . . . . . . . . . . 94 Engine . . . . . . . . . . . . . . . . . . 87-93 Front Gearcase . . . . . . . . . . . . . . . 94 Main Gearcase . . . . . . . . . . . . . . . 95 Transmission . . . . . . . . . . . . . . . . 95 Oil and Filter Care During Storage. 129 Oil Change Demand Drive . . . . . . . . . . . . . . . 94 Engine (570). . . . . . . . . . . . . . 92-93 Engine Oil (325). . . . . . . . . . . 89-90 Front Gearcase . . . . . . . . . . . . . . . 94 Main Gearcase . . . . . . . . . . . . . . . 95 Transmission . . . . . . . . . . . . . . . . 95 Oil Check Demand Drive . . . . . . . . . . . . . . . 94 Engine Oil (325). . . . . . . . . . . . . . 88 Engine Oil (570). . . . . . . . . . . . . . 91 Front Gearcase . . . . . . . . . . . . . . . 94 Main Gearcase . . . . . . . . . . . . . . . 95 Transmission . . . . . . . . . . . . . . . . 95 P Parking on an Incline . . . . . . . . . . . . 65 Parking the Vehicle. . . . . . . . . . . . . . 55 Periodic Maintenance Chart . . . . 81-84 Plug Condition . . . . . . . . . . . . . . . . . 97 Plug Gap . . . . . . . . . . . . . . . . . . . . . . 96 Plug Torque . . . . . . . . . . . . . . . . . . . 96 Plug, Accessory . . . . . . . . . . . . . . . . 31 Plug, Spark . . . . . . . . . . . . . . . . . 96-97 Plugs, Fouled . . . . . . . . . . . . . . . . . . 97 Polaris Products . . . . . . . . . . . . . . . 134 Polishing the Vehicle . . . . . . . . . . . 127 Power Steering . . . . . . . . . . . . . . . . . 27 Power Steering Unit (Cleaning) . . . . 99 Pre-Filters, Intake . . . . . . . . . . . . . . 107 Pre-Ride Inspection . . . . . . . . . . . . . 51 Public Lands . . . . . . . . . . . . . . . . . . . 80 PVT Break-In . . . . . . . . . . . . . . . . . . 50 PVT Drying . . . . . . . . . . . . . . . . . . 105 PVT Intake Pre-Filter . . . . . . . . . . . 107 PVT System Operation . . . . . . 103-105 PVT, Cleaning Debris. . . . . . . . . . . 104 R Radiator. . . . . . . . . . . . . . . . . . . . . . 101 Radiator Access . . . . . . . . . . . . . . . . 25 Radiator Coolant Level. . . . . . . . . . 101 Receiver Hitch . . . . . . . . . . . . . . . . . 25 Refueling Safety . . . . . . . . . . . . . . . . 22 Registration, Warranty . . . . . . . . . . 139 Removal, Battery . . . . . . . . . . . . . . 121 Removal, Seat . . . . . . . . . . . . . . . . . . 28 Removal, Wheels . . . . . . . . . . . . . . 116 Removing the Vehicle from Storage 131 Restrictions, Age. . . . . . . . . . . . . . . . 14 Reverse . . . . . . . . . . . . . . . . . . . . . . . 65 Rider Information Center . . . . . . 38-43 Riding Area. . . . . . . . . . . . . . . . . . . . 53 Riding Gear. . . . . . . . . . . . . . . . . . . 8-9 Rollover Protective Structure . . . . . . 34 ROPS Cab Frame . . . . . . . . . . . . . . . 34 149 INDEX S T Safe Operation Practices . . . . . . . 52-53 Safety Labels . . . . . . . . . . . . . . . . 10-13 Safety Symbols . . . . . . . . . . . . . . . . . 4 Safety Training . . . . . . . . . . . . . . . . . 7 Safety Training, ROHVA . . . . . 52, 56 Safety Warnings. . . . . . . . . . . . . . 14-23 Safety, Winch Maintenance. . . . . . . 79 Seat Adjustment. . . . . . . . . . . . . . . . 28 Seat Belt. . . . . . . . . . . . . . . . . . . . . . 29 Seat Removal . . . . . . . . . . . . . . . . . . 28 Selector, Gear . . . . . . . . . . . . . . . . . 32 Service Panels . . . . . . . . . . . . . . . . . 25 Severe Use Definition . . . . . . . . . . . 81 Shifting Gears . . . . . . . . . . . . . . . . . 32 Shock Loading the Winch . . . . . . . . 78 Signal Words . . . . . . . . . . . . . . . . . . . 4 Spark Arrester, Cleaning . . . . . . . . 108 Spark Plug . . . . . . . . . . . . . . . . . . 96-97 Spark Plug Condition. . . . . . . . . . . . 97 Spark Plug Gap . . . . . . . . . . . . . . . . 96 Spark Plug Removal . . . . . . . . . . . . 97 Spark Plug Torque . . . . . . . . . . . . . . 96 Spark Plugs, Fouled . . . . . . . . . . . . . 97 Specifications. . . . . . . . . . . . . . . . . 132 Specifications, Gearcase . . . . . . . . . 96 Speed, Towing . . . . . . . . . . . . . . . . . 68 Speedometer . . . . . . . . . . . . . . . . . . 36 Spring Adjustment, Rear Shock . . 114 Stabilizing the Fuel . . . . . . . . . . . . 129 Starting the Engine . . . . . . . . . . . . . 54 Steering Wheel Adjustment. . . . . . . 26 Steering Wheel Inspection. . . . . . . 114 Stopping the Engine. . . . . . . . . . . . . 55 Storage . . . . . . . . . . . . . . . . . . . 126-131 Storage and Inspection. . . . . . . . . . 130 Storage and Lubrication. . . . . . . . . 130 Storage Area . . . . . . . . . . . . . . . . . 130 Storage, Battery . . . . . . . . . . . . . . . 123 Storage, Covers . . . . . . . . . . . . . . . 130 Storage, Fluid Levels . . . . . . . . . . . 129 Storage, Oil and Filter . . . . . . . . . . 129 Storage, Removal. . . . . . . . . . . . . . 131 Switches AWD Switch. . . . . . . . . . . . . 31, 35 Ignition Switch . . . . . . . . . . . . . . 31 Light Switch . . . . . . . . . . . . . . . . 31 Mode Button . . . . . . . . . . . . . . . . 36 Tachometer . . . . . . . . . . . . . . . . . . . . 41 Throttle Freeplay . . . . . . . . . . . . . . . 109 Throttle Freeplay Adjustment . . . . . 110 Throttle Freeplay Inspection . . . . . . 109 Throttle Pedal . . . . . . . . . . . . . . . . . . 33 Throttle System . . . . . . . . . . . . . . . . 109 Tire Tread Depth . . . . . . . . . . . . . . . 115 Tires . . . . . . . . . . . . . . . . . . . . . 115-116 Torque, Axle Nuts . . . . . . . . . . . . . . 115 Torque, Spark Plug . . . . . . . . . . . . . . 96 Torque, Wheel Nut . . . . . . . . . . . . . 115 Towing an ACE . . . . . . . . . . . . . . . . . 67 Towing Loads . . . . . . . . . . . . . . . . . . 68 Towing Speed . . . . . . . . . . . . . . . . . . 68 Trail Etiquette . . . . . . . . . . . . . . . . . . 53 Trailer Hitch . . . . . . . . . . . . . . . . . . . 25 Training . . . . . . . . . . . . . . . . . . . . . . . . 7 Transmission Oil . . . . . . . . . . . . . . . . 95 Transmission Operation. . . . . . 103-105 Transmission, Drying . . . . . . . . . . . 105 Transporting the Vehicle . . . . . . . . . 131 Tread Depth, Tire . . . . . . . . . . . . . . 115 Tread Lightly . . . . . . . . . . . . . . . . . . . 53 Turning the Vehicle . . . . . . . . . . . . . . 58 150 V Vehicle Identification Numbers. . . . . . 6 Vehicle Immersion . . . . . . . . . . . . . 119 Vehicle Transport . . . . . . . . . . . . . . 131 W Warning Symbols . . . . . . . . . . . . . . . . 4 Washing the Vehicle . . . . . . . . 126-127 Water, Immersion of Vehicle . . . . . 119 Wear, Drive Belt . . . . . . . . . . . . . . . 135 Weight, Hitch. . . . . . . . . . . . . . . . . . . 68 Wheel Installation . . . . . . . . . . . . . . 116 Wheel Nut Torque . . . . . . . . . . . . . . 115 Wheel Removal . . . . . . . . . . . . . . . . 116 Winch Cable Care . . . . . . . . . . . . . . . 77 Winch Maintenance/Service Safety. . 79 Winch Operation . . . . . . . . . . . . . 72-76 Winch Safety Precautions . . . . . . 69-71 Winch Shock Loading . . . . . . . . . . . . 78 PMS 419 WARNING Improper vehicle use can result in SEVERE INJURY or DEATH NEVER Operate: • If you are under age 16 and without a valid driver’s license. • Without first viewing safety video and taking a ROHVA training course at www.rohva.org. • On excessively steep hills. • On public roads (unless designated for off-road use). • On paved surfaces - pavement may seriously affect handling and control. • With non-Polaris approved accessories - they may seriously affect stability. ALWAYS: • Wear your seat belt. Vehicle rollover can cause severe injury or death. • Secure cab nets or doors and keep hands and feet inside vehicle at all times. • Wear a helmet, eye protection, gloves, long-sleeve shirt, long pants and over-the-ankle boots. • Avoid sharp turns or turns while applying heavy throttle. • Operate slowly in reverse - avoid sharp turns or sudden braking. RIDER MUST WEAR AN APPROVED HELMET AND PROTECTIVE GEAR. RIDER MUST WEAR SEAT BELT. NEVER USE ON PUBLIC ROADS. NEVER USE WITH DRUGS OR ALCOHOL. READ OWNER’S MANUAL. FOLLOW ALL INSTRUCTIONS AND WARNINGS. For your nearest Polaris dealer, call 1-800-POLARIS (765-2747) or visit www.polaris.com Polaris Industries Inc. 2100 Highway 55 Medina, MN 55340 Part No. 9926060 Rev 01 Printed in USA