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Polaris 9922483 Offroad Vehicle User Manual

1. 119 Fluid Conventional 118 Installation 0 117 R emoyal 4 5 ceecevr gare es 116 Storages o iere tee RR RR 118 Belt Life esee SS 33 BOOS scena aa E AE SNE 9 Brake Fluid Main Brake System 31 Brake Lever Auxiliary 30 Brake Lever Service 30 Brake Systems 20 30 Brake Parking 32 Brakelight 2 cs terere 107 BEAK eS cett ve PERLES 96 Break In Period 46 47 C Camber Adjustment 128 CAL Oise terhome pus Davon e Snead 62 64 Cargo Capacities 62 Caster Adjustment 128 Changing the Oil Middle Gearcase 91 Checking the Oil Middle Gearcase 91 Chrome Wheel Care 123 Cleaning and Storage 121 126 CIotlIHg err card rerit aw eice deg 9 Clutching este eem 135 C COdES eee erre eee ERES 43 45 Cold Weather Operation 51 Coolant Bottle 0 94 Coolant Radiator 95 Cooling System 94 95 Corrosion Removal Chrome 123 D Demand Drive Capacities 88 Demand Drive Fluid 88 89 Disengaging Active Descent Control 36 Downloading Codes 43 45 Drive Belt Wear Burn 130 Drivetrain Break In 47 Driving Downhill 57 Driving in Reverse 61 Driving on a Sidehill 56 Driving on Slippery Surfaces 54 Driving Over Obstacles
2. 100 Wheel Removal 99 Toe Alignment 97 Trail Etiquette 2 0 000 50 TRAM 5s Receta Sedo 7 Transmission Gear Selector 33 Transmission Oil 87 Transporting the Vehicle 127 Tread Lightly a sere 50 Turning Around on aHill 58 Turning the Vehicle 53 V Vehicle Identification Numbers 6 Vehicle Immersion 110 WwW Warning Symbols 4 Washing the Vehicle 121 122 Wheel Hub Tightening 99 Wheel Installation 100 Wheel Nut Torque Specifications 100 Wheel Removal 99 Winch Cable Care 74 Winch Maintenance Service Safety 77 Winch Operation 69 73 Winch Safety Precautions 66 68 Winch Shock Loading 75 76 145 Before you operate this vehicle read the owner s manual POLARIS For your nearest Polaris dealer call 1 800 POLARIS or visit www polaris com Polaris Sales Inc 2100 Hwy 55 Medina MN 55340 USA c r Part No 9924416 Rev 01 zn Printed in USA 4 a
3. 60 Driving Procedures 52 Driving Through Water 59 Driving Uphill 55 Dumping Cargo 64 E Electromagnetic Interference 78 Engaging Active Descent Control 36 Engaging AWD 35 Engine Break In 47 Engine Fogging 125 Engine Oil esee Rev 84 86 Equipment Modifications 9 Etiquette Trail Riding 50 European Vibration and Noise 78 Exhaust Emission Control System 78 Eye Protection 9 143 INDEX F Fluid ADG vce ub aoi a eats 92 93 Bfakez cres E ewe e 3l Demand Drive 88 89 Fluid Change ADG o rae Ronn tet etu Ese 93 Demand Drive 89 Footwell Removal 98 Front Gearcase Demand Drive 88 89 Fuel Safety i sse RR Re va 11 Fuel Tank Cap 6 33 Fuse Replacement 102 G Gasoline Handling 11 Gear Selector ie cafe eene 33 Gearcase Oil Middle 91 Gearcase Oil Rear 90 So CPP 9 H Handlebar Adjustment 128 Hauling Cargo suse 62 64 Headlight Housing Replacement 106 Headlight Lamp Replacement 103 Headlight Switch 27 Helmet o bt tre ra 8 High Beam Adjustment 104 High Range Use 114 l Idle RPM Adjustment 129 Immersion 0000 110 Instrument Cluster 37 45 K Ke
4. 113 MAINTENANCE PVT System PVT Operation The air temperature in the clutch cover is substantially reduced by using low range while operating at low ground speeds Reducing the tempera ture inside the clutch cover greatly extends the life of the PVT compo nents belt cover etc When To Use Low Range and High Range Condition Range to Use Operating at speeds less than 7 MPH 11 km h Low Towing heavy loads Low Operating in rough terrain swamps mountains etc Low Operating at speeds greater than 7 MPH 11 km h High 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 operat ing 1 Position the vehicle on a level surface 2 Remove the drain plug Allow the water to drain completely Rein stall the drain plug 3 Start the engine Place the transmission in park 4 Apply varying throttle for 10 15 seconds to expel the moisture and air dry the belt and clutches Do not hold the throttle wide open for more than 10 seconds 5 Allow the engine RPM to settle to idle speed then shift the trans mission to the lowest available range 6 Test for belt slippage If the belt slips repeat the process 7 Take the vehicle to your dealer for service as soon as possible 114 MAINTENANCE Battery A WARNING Improperly connecting or disconnecting battery cables can result in an explosion and c
5. Master Cylinders 1 Position the vehicle on a level surface 2 Position the handlebars so the master cylinders are level 3 View the brake fluid level through the indicator window on the top of the master cylinder The eye will appear dark when the fluid level is full When fluid is low the eye will be clear 4 If the fluid level is low add DOT 4 brake fluid only Do not overfill 31 FEATURES AND CONTROLS Parking Brake Locking the Parking Brake 1 Place the transmission in park 2 Squeeze and release the brake lever two or three times then squeeze and hold 3 Push the parking brake lock forward to engage the lock 4 Release the brake lever 5 To release the parking brake lock squeeze and release the brake lever It will return to its unlocked position WARNING Operating the vehicle while the parking brake is engaged could result in an accident or fire Always check to be sure the parking brake is disengaged before operating The parking brake may relax if left on for a long period of time Always block the wheels to prevent rolling Always block the wheels on the downhill side of the vehicle if leaving it parked on a hill Another option is to park the vehicle in a sidehill position Never depend on the parking brake alone if the vehicle is parked on a hill Always block the wheels to prevent rolling UTI 8 essi 32 FEATURES AND CONTROLS Automatic Transmission Gear Selector The transmission
6. Odometer Tachometer Tripmeter Hour Meter 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 will flash FUEL will display in the LCD and the speedometer needle will blink Refuel immediately Check Engine Warning Indicator This indicator serves two pur poses The word HOT displays if the engine overheats It also appears if an EFI related fault occurs Do not operate the vehicle if this warning appears Serious engine damage could result Mode Indicator FEATURES AND CONTROLS Instrument Cluster Rider Information Center Standard Modes Use the MODE button to toggle through the mode options The reverse override button is also the MODE button See page 26 The transmission cannot be in reverse when using this feature Odometer Mode The odometer records the miles traveled by the vehicle Trip Meter Mode The trip meter records the miles traveled by the vehicle on each trip if it s reset before each trip To reset the trip meter select the trip meter mode Press and hold the mode button override button until the total changes to 0 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 Tachometer Mode The engine RPM is displayed digitally Small fluctuatio
7. 115 MAINTENANCE Battery Battery Removal Remove the seat Disconnect the battery hold down strap On conventional batteries remove the battery vent tube Disconnect the black negative battery cable first Disconnect the red positive battery cable last Lift the battery out of the vehicle Be careful not to tip a conven tional battery sideways which could spill electrolyte NOTICE f electrolyte spills immediately wash it off with a solution of one tablespoon baking soda and one cup water to prevent damage to the vehicle De eo 116 MAINTENANCE Battery Battery Installation Using a new battery that has not been fully charged can damage the bat tery and result in a shorter life It can also hinder vehicle performance Follow the battery charging instructions on page 119 before installing the battery 1 Ensure that the battery is fully charged 2 Place the battery in the battery holder 3 With conventional batteries install the battery vent tube sealed bat teries 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 Onconventional batteries
8. Tires Pressure Front Off Road Style Deep Tread Design Size 25x8 12 7 psi 48 3 kPa Tires Pressure Center Off Road Style Deep Tread Design Size 25x11 12 10 psi 68 9 kPa Tires Pressure Rear Off Road Style Deep Tread Design Size 25x11 12 10 psi 68 9 kPa Brakes Front Hydraulic Disc Brakes Rear Hydraulic Disc Brakes Auxiliary Hydraulic Disc Brake Parking Hydraulic lock on all wheels Mechanical Lock in Park Hitch Rear mounting for attachment of coupling devices Winch Front permanent Installed winch with 2500 Ibs 1 125 kg Capacity Headlight 1 Single Beam on Headlight Pod 50 watt 2 Single Beam on Bumper 50 watt Taillights 8 26 watts Brake Light 26 9 watts Instrument Cluster LCD Clutching Altitude Shift Drive Clutch Driven Helix Weight Spring Clutch Spring Meters 0 1800 21 74 Red White Red EBS Feet 0 6000 PN 5632117 PN 7043372 PN 3234452 PN 3234604 1800 3700 21 70 Red White Red EBS 6000 12000 PN 5632127 PN 7043349 PN 3234452 PN 3234604 EBS models require no helix spring adjustment 135 POLARIS PRODUCTS dits Description Engine Lubricant 2870791 Fogging Oil 12 oz Aerosol 2876244 PS 4 Full Synthetic 5W 50 4 Cycle Oil qt 95 I 2876245 PS 4 Full Synthetic 5W 50 4 Cycle Oil gal 3 8 2878920 PS 4 Extre
9. when the switch is off Both the main switch and the engine stop switch will shut off all electri cal power to the vehicle including lights Main Key Switch Use the main key switch to start the engine See page 51 for starting pro cedures Headlight Switch Use the headlight switch to turn the lights on and off and to change the lights from high beam to low beam The key must be in the ON position and the engine stop switch must be in the RUN position to operate the headlights 27 FEATURES AND CONTROLS Throttle Lever A WARNING Operating this vehicle with sticking or improperly operating throttle controls could cause an accident Never start or operate the vehicle if it has a sticking or improperly operating throttle Always contact your dealer for service before operating the vehicle Failure to check or maintain proper operation of the throttle system can result in an accident if the throttle lever sticks during operation Always check the lever for free movement and return before starting the engine Also check occasionally during operation Engine speed and vehicle movement are controlled by pressing the am S throttle lever The throttle lever is C o LS ara spring loaded Engine speed returns eum n y to idle when the lever is released p 3 tmo This vehicle is equipped with a o throttle release switch which is Ee A designed to reduce the risk of a wot frozen or stuck throttle If the thr
10. 5 If carbon comes out of the exhaust cover or plug the 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 Lock the parking brake 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 111 MAINTENANCE PVT System A 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 Extensive engineering and testing has been conducted to ensure the safety of this product However as the owner you have the following responsibilities to make sure this system remains safe 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 dealer
11. IF OWNER S MANUAL IS MISSING CONTACT A POLARIS DEALER FOR A REPLACEMENT 22 SAFETY Safety Labels and Locations Reverse Override General Warning Tire Pressure Load Warning Warning Front R ck anaes Warning Tire Pressure Load Warning WARNING Improper tire pressure or overloading can cause loss of control Loss of control can result in severe injury or death Cold tire pressure Front 7 0 psi 48 3 kPa Center 10 0 psi 68 9 kPa Rear 10 0 psi 68 9 kPa Maximum weight capacity 1115 lbs 507 kg Front Rack Box Warning WARNING DO NOT TOW FROM RACK OR BUMPER Vehicle damage or tipover may result causing severe injury or death Tow only from tow hooks or hitch Max Rack Loads 100 Ibs 45 kg Reverse Override Warning WARNING Improper use of override button can lead to loss of control resulting in severe injury or death Do not activate override while throttle is engaged Always apply throttle gradually while in reverse 23 SAFETY Safety Labels and Locations Age 16 Warni ii e Container No Passenger Warning x 8X6 ENG SuSE Clutch Cover Warning Container No Passenger Warning WARNING Remove flammable containers from box before refueling WARNING Passengers can be thrown off This can cause serious injury or death Never carry passengers Maximum Box Load 800 Ibs 363 kg 24 SAFETY Safety Labels and
12. Improper adjustment of the handlebars or incorrect torquing of the adjuster block tightening bolts can cause limited steering or loosening of the handlebars resulting in loss of control and serious injury or death Follow the adjustment procedures exactly or see your POLARIS dealer for service 1 Remove the upper headlight pod 2 Loosen the four handlebar bolts 3 Adjust the handlebar to the desired height Be sure the handlebars do not contact the gas tank or any other part of the machine when turned fully to the left or right 4 Torque the front two bolts to 10 12 ft lbs 14 17 Nm then Handlebar torque the rear two bolts A Bolts gap of up to 1 8 3 mm will remain at the rear of the clamp blocks 128 Throttle Body Idle RPM MAINTENANCE Idle RPM is preset by the manufacturer If the engine idle speed is not satisfactory please see your POLARIS dealer for adjustment Throttle Cable Freeplay Adjust throttle cable freeplay at the handlebar 1 2 Locate the throttle cable adjuster at the handlebar Squeeze the end of the rub ber boot and slide it far enough to expose the end of the inline cable adjuster Loosen the adjuster lock nut Rotate the boot to turn the adjuster until 1 16 to 1 8 1 5 3 mm of freeplay is achieved at the thumb lever While adjusting freeplay be sure to flip the throttle lever back and forth Tighten the lock nut Squeeze the end of the rub ber boot
13. K Turn If the vehicle stalls while climbing a hill never back it down the hill Use the K turn to turn around 58 8 ft 2 4 m Stop and lock the parking brake while keeping body weight uphill Always move the 4X4 switch to ADC 4X4 if equipped before ascending or descending a hill See page 36 Leave the transmission in forward and shut off the engine Dismount on the uphill side of the vehicle or on the left if the vehi cle is pointing straight uphill Staying uphill of the vehicle turn the handlebars full left While holding the service brake release the parking brake lock and slowly allow the vehicle to roll around to your right until it s point ing across the hill or slightly downward Lock the parking brake and remount the vehicle from the uphill side keeping body weight uphill Restart the engine with the transmission still in forward Release the parking brake and proceed s owly controlling speed with the service brake until the vehicle is on more level ground OPERATION Driving Through Water Your vehicle can operate through water with a maximum recommended depth equal to Pa the bottom of the footrests Fol j low these procedures when operating through water 1 Determine water depths and current before entering water 2 Choose a crossing where Pac A d both banks have gradual Maximum inclines Depth 3 Avoid operating through deep or fast flowing water NOTICE Maj
14. 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 122 MAINTENANCE Cleaning and Storage Chrome Wheel Care if equipped Proper maintenance will protect chrome wheels from corrosion pre serve wheel life and ensure a like new appearance for many years Chrome wheels exposed to road salt or salt in the air in coastal areas are more susceptible to corrosion if not properly cleaned Clean chrome wheels more often if they re exposed to salt or other corrosive elements 1 Wash chrome wheels frequently Use a mild detergent Never use abrasive cleaners on plated or painted surfaces 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 pol ished 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 rem
15. The friction provided by this wrapped cable allows the drum to pull on the winch cable and move the load 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 66 WINCH GUIDE Winch Safety Precautions 11 12 13 14 15 16 17 18 19 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 If winching at an angle is unavoidable follow these precautions A 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 B If stacking occurs stop winching Follow step 15 on page 73 to feed and rewind the cable evenly before continuing the winch operation Never winch up or down at sharp angles This can destabilize the winching vehicle and possibly cause it to move without warning Never attempt to winch loads that weigh more than the winch s rated capacity 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 Never touch push pull or straddle the winch
16. Using an oil filter wrench available from your POLARIS dealer turn the filter counter clockwise to remove it Using a clean dry cloth clean the filter sealing surface on the crankcase 85 MAINTENANCE Engine Oil Oil and Filter Change 10 11 12 13 14 15 16 17 18 19 20 86 Lubricate the o ring on the new filter with a film of fresh engine oil Check to make sure the o ring is in good condition Install the new filter and rotate it clockwise by hand until the filter gasket contacts the sealing surface then turn it an additional 1 2 turn Remove the dipstick Add two quarts 1 9 I of recommended oil Place the transmission in park Lock the parking brake Start the engine Allow it to idle for one to two minutes Stop the engine Check for leaks Check the oil level Add oil as needed to bring the level to the upper mark on the dipstick Dispose of used filter and oil properly MAINTENANCE Transmission Oil Always check and change the transmission oil at the intervals outlined in the Periodic Mainte nance Chart beginning on page 79 Maintain the oil level at the bottom of the fill plug hole The fill plug is located on the right side of the ATV behind the footwell The drain plug is located on the bottom Shogo left side of the gearcase N POLARIS recommends the use of Fill L vel AGL Gearcase Lubricant amp Trans
17. bear the ECE 22 05 label The ECE mark consists of a circle surrounding the letter E followed by the distinguishing number of the country which has 051039 granted approval The approval number and serial 0006 31 number will also be displayed on the label SAFETY Safe Riding Gear Eye Protection Do not depend on eyeglasses or sunglasses for eye protection When ever riding a 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 Off road style gloves with knuckle pads are the best for comfort and protection Boots The best footwear is a pair of sturdy over the calf boots with low heels Clothing Always wear long sleeves and long pants to protect arms and legs Rid ing pants with kneepads and a jersey with shoulder pads provide the best protection Equipment Modifications We strongly recommend that consumers do not install on a POLARIS vehicle any equipment that may increase the speed or power of the vehi cle or make any other modifications to the vehicle for these purposes The warranty on your POLARIS vehicle is terminated if any equipment has been added to the vehicle or if any modifications have been made to the vehicle that increase its speed or power The addition of certain accessories includ
18. 5 The adjustment knob is located on the right side of the headlight pod Adjust the beam to the desired position by turning the knob either clockwise or counter clockwise 104 MAINTENANCE Lights Low Beam Adjustment The low beam can be adjusted slightly upward or downward 1 Loosen the phillips screw located at the rear of the headlamp 2 Tilt the headlamp upward or down ward 3 Tighten the screw Phillips Screw 105 MAINTENANCE Lights Headlight Housing Replacement 1 Remove the two screws on the lower front corners of the headlight pod 2 Liftthe pod slightly while depressing the tabs at the rear of the pod 3 Liftthe pod cover and disconnect the speedometer harnesses from the speedometer 4 Unplug the headlamp from the wiring harness 5 Useasmall screwdriver to remove the o rings from the headlight mounting tabs 6 Pull the headlight housing up to release it from the locking tabs 7 Liftthe adjusting knob up to remove it from the locking tabs 8 Carefully pull the assembly up and out of the pod 9 Reverse the steps to install the new housing and reassemble the pod The distance from the headlamp parting line to the end of the adjustment knob stop is 5 1 8 13 cm 10 Adjust the headlight aim by turning the adjusting knob 106 MAINTENANCE Lights Lower Headlamp Replacement 1 Turn the back of the headlight harness counter clockwise and pull the harness assembly awa
19. Drain Plug mission Fluid for this transmission See page 136 for the part numbers of POLARIS products Access the transmission fill plug from the right side of the vehicle Access the drain plug from the left side of the vehicle Oil Check 1 Position the vehicle on a level surface 2 Remove the footwell see page 98 3 Remove the fill plug Check the oil level 4 Reinstall the fill plug Torque to 14 ft Ibs 19 Nm 5 Reinstall the footwell Oil Change 1 Remove the footwell see page 98 2 Place a drain pan under the gearcase Remove the drain plug Allow the oil to drain completely Clean and reinstall the drain plug Torque to 14 ft Ibs 19 Nm Remove the fill plug Add 15 oz 450 ml of the recommended oil Reinstall the fill plug Torque to 14 ft Ibs 19 Nm Check for leaks Reinstall the footwell Dispose of used oil properly 9o cubos We quo co 87 MAINTENANCE Front Gearcase Demand Drive Fluid Always check and change the demand drive fluid at the intervals out lined in the Periodic Maintenance Chart beginning on page 79 We rec ommend the use of POLARIS Demand Drive Fluid Use of other fluids may result in improper operation of components See page 136 for the part numbers of POLARIS products Change the front gearcase fluid every 25 hours if the ADC unit is exposed to extreme use Extreme use includes any of the following operation in ADC mode for prolonged periods constant ADC
20. Ground 52 Injector Circuit Malfunction Cyl 2 Shorted Load Short to Battery 55 MIL Circuit Open Load Short to Ground 55 MIL Circuit Shorted Load Short to Battery 56 Fuel Pump Open Load Short to Ground 56 Fuel Pump Shorted Load Short to Battery 58 Fan Circuit Open Load Short to Ground 58 Fan Circuit Shorted Load Short to Battery 59 ADC Open Load Short to Ground 59 ADC Shorted Load Short to Battery 63 Starter Enable Open Load Short to Ground 63 Starter Enable Shorted Load Short to Battery 72 Gear Sensor Signal 73 4X4 Open Load Short to Ground 73 4X4 Shorted Load Short to Battery 74 Rear Differential Enable Open Load Short to Ground if equipped 74 Rear Differential Enable Shorted Load Short to Battery if equipped 61 END SEQUENCE 45 OPERATION Failure to operate the vehicle properly can result in a collision loss of control accident or overturn which may result in serious injury or death Read and understand all safety warnings outlined in the safety section of this owner s manual Break In Period The break in period for your new POLARIS vehicle is the first ten hours of operation or the time it takes to use the first two full tanks of gaso line No single action on your part is as important as following the pro cedures for a proper break in Careful treatment of a new engine and drive components will result in more efficient performance and longer life for these components NOTICE Excessive heat build up
21. Locations Age 16 Warning WARNING Operating this ATV if you are under the age of 16 increases your chance of severe injury or death NEVER operate this ATV if you are under age 16 Clutch Cover Warning WARNING Moving parts hazard under belt clutch guard To prevent serious injury do not operate vehicle with guard removed Do not modify engine or clutch Doing so can cause part failure possible imbalance and excessive engine RPM which can result in serious injury or death NO STEP 25 FEATURES AND CONTROLS Switches i Engine Headlight Switch Stop Switch Mode Reverse Main Key Switch M Winch Switch Mode Reverse Override Switch This vehicle is equipped with a reverse speed limiter system To gain additional wheel speed while backing release the throttle and depress the override button WARNING Pressing the override button while the throttle is open can cause loss of control which may result in serious injury or death Always release the throttle before pressing the override button The override switch is used to toggle through the modes of the rider information center See page 37 All Wheel Drive AWD Switch See page 34 for AWD information Winch Switch See page 66 for winch information 26 FEATURES AND CONTROLS Switches Engine Stop Switch i Move the stop switch either qa left or right to the OFF position g to stop the engine quickly The V engine will not start or run OFF RUN OFF
22. 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 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 137 WARRANTY 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
23. 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 138 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 From 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 m
24. Wipe it dry with a clean cloth 3 Reinstall the dipstick com pletely but do not lock it The dipstick must be inserted com pletely to keep the angle and depth of the stick consistent 4 Remove the dipstick and check the oil level Maintain the oil level in the safe range Do not overfill Tip Due to the dipstick entry angle into the crankcase the oil level will read higher on the bottom side of the dipstick Always read the level on n upper surface of the dip stick l O Check Level 5 After reinstalling the dipstick on Top Side seat the lever lock 84 MAINTENANCE Engine Oil Oil and Filter Change Always change the oil and filter at the intervals outlined in the Periodic Maintenance Chart beginning on page 79 Always change the oil filter whenever changing oil l 2 Position the vehicle on a level surface Start the engine Allow itto warm up at Drain Plug Location idle for two to three minutes Stop the engine Clean the area around the drain plug Place a drain pan under the crankcase Remove the drain plug Allow the oil to drain completely CAUTION Hot oil can cause burns to skin Do not allow hot oil to contact skin 6 Install a new sealing washer on the drain plug The sealing surfaces on drain plug and crankcase should be clean and free of burrs nicks or scratches Reinstall the drain plug Torque to 20 ft lbs 27 Nm Place shop towels beneath the oil filter
25. a possible fluid leak or low master cylinder fluid level which must be corrected before riding Contact your dealer for proper diagnosis and repairs JUI ogee z a Auxiliary Brake Lever Squeeze the auxiliary brake lever right lever toward the handlebar to apply the middle axle rear brake only Use the auxiliary brakes for addi tional braking or for backup if the S v service brake system fails Cm WIL Zr amp If the rear wheels slide while A EaP J jJ using the auxiliary brake reduce Ap o e a eae I brake lever pressure to brake the koer rear wheels without skidding SY 30 FEATURES AND CONTROLS Master Cylinder Brake Fluid A WARNING An over full master cylinder may cause brake drag or brake lock up which could result in an accident Maintain brake fluid at the recommended level Do not overfill Never store or use a partial bottle of brake fluid Brake fluid is hygroscopic meaning it rapidly absorbs moisture from the air The moisture causes the boiling temperature of the brake fluid to drop which can lead to early brake fade and the possibility of brake failure which could result in an accident After opening a bottle of brake fluid always discard any unused portion The master cylinders are located on the left and right handlebars Check the fluid levels of both master cylinders before each use of the vehicle Indicator Windows is
26. as outlined in the owner s manual This PVT system is intended for use on POLARIS products only Do not install itin any other product Always make sure the PVT housing is securely in place during operation 112 MAINTENANCE PVT System PVT Operation The basic operation of the POLARIS PVT system is dependent on engine speed and vehicle torque requirements As engine speed increases the force exerted on the movable drive sheave by the fly weights also increases This in turn increases the amount of pinch applied to the drive belt Similarly if the engine speed decreases the amount of centrifugal force decreases reducing the amount of belt pinch The approximate gear ratio difference between high and low range is 1 2 25 This difference in gearing affects the operation of the PVT espe cially at speeds less than 7 MPH 11 km h due to the system s depen dence on engine speed For example when operating at a ground speed of 3 MPH 5 km h in low range the engine speed would be around 3000 RPM This is well above the engagement speed of 1200 1400 RPM However in high range at 3 MPH 5 km h the engine would be running at only 1500 RPM Whenever operating this close to the engagement speed the engine may be running at a speed too low to provide the pinch needed to prevent belt slip Belt slip is responsible for creating the excessive heat that destroys belts wears clutch components and causes outer clutch covers to fail
27. at all times The friction provided by this wrapped cable allows the drum to pull on the winch cable and move the load Read and adhere to the following information for winch damping to ensure safe winch use A 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 B Laythe damper on top of the mid point of the winch cable length that is spooled out C Onalong 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 D 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 Never hook the winch cable back onto itself This will damage the winch cable and may result in winch cable failure Never use straps chains or other rigging items that are damaged or worn 71 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 winch equipped vehicle should NEVER be in motion to shock load th
28. battery voltage is 12 8 or greater 3 When using an automatic charger refer to the charger manufac turer s instructions for recharging When using a constant current charger use the guidelines on the next page for recharging 119 MAINTENANCE Battery Battery Charging Sealed Battery Always verify battery condition before and 1 2 hours after the end of charging State of Charge TE Voltage Action Using constant current Charge charger standard amps specified on top of battery 10096 12 8 13 0 volts None check at 3 None required mos from date of manufacture 75 100 12 5 12 8 volts May need slight 3 6 hours charge if no charge given check in 3 months Needs charge 5 11 hours 50 75 12 0 12 5 volts 25 50 11 5 12 0 volts Needs charge At least 13 hours verify state of charge 0 25 11 5 volts or less Needs charge with desulfating charger At least 20 hours 120 MAINTENANCE Cleaning and Storage Washing the Vehicle Keeping your POLARIS vehicle clean will not only improve its appear ance but it can also extend the life of various components NOTICE High water pressure may damage components POLARIS recommends washing the vehicle by hand or with a garden hose using mild soap 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 saf
29. damage from leak ing or spilled electrolyte during charging See page 116 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 grav ity to 1 270 or greater 3 Reinstall the battery See page 117 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 installa tion 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 Tip 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 Ifthe voltage is less than 12 8 volts recharge the battery at 1 2 amps or less until
30. designed or not intended including but not limited to the following items Finished and unfinished surfaces Carburetor Throttle body components Engine components Drive belts Hydraulic components and fluids Circuit breakers Fuses Wheels and tires Suspension components Brake components Seat components Clutches and components Steering components e o o o o oo o e o o o o o o o Batteries Electronic components Light bulbs Sealed beam lamps Spark plugs Filter Sealants Lubricants Coolants Bushings 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
31. equivalent accessories designed for use on this vehicle 63 OPERATION Hauling Cargo Dumping Cargo 1 Select a level site to dump the cargo Do not attempt to dump or unload the vehicle while parked on an incline 2 Lock the parking brake Dismount the vehicle Ead 4 Check cargo distribution If cargo has shifted to the rear of the box exercise caution WARNING If the weight distribution in the box is located toward the rear of the box when the release lever is pulled forward the box may dump on its own which could cause serious injury Never operate the dump lever without checking the position of the load This will prevent unexpected dumping of the cargo box Never carry passengers in the cargo box Release Levers 5 Pullthe cargo box release lever forward 6 Liftthe front of the cargo box to dump the cargo 7 Lower the cargo box Make sure the latch is secure before operating WARNING Operating with the cargo box in the raised position can cause serious injury and damage to the vehicle The cargo box could close unexpectedly and injure the driver The rear tires will also catch the rear of the box damaging the vehicle and creating hazardous driving conditions Never operate this vehicle with the cargo box in the raised position 64 OPERATION Parking on an Incline Avoid parking on an incline if possible If it s unavoidable follow these precautions 1 2 3 4 Stop the e
32. filter with a new filter Remove the spark plugs Turn the engine over several times using the electric start Dry the spark plugs Reinstall the plugs or install new plugs Attempt to start the engine If necessary repeat the drying proce dure Take the vehicle to your dealer for service as soon as possible whether you succeed in starting it or not If water has been ingested into the PVT follow the procedure on page 114 for drying out the PVT MAINTENANCE Spark Arrester A 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 Remove the arrester clean out plug from the bottom of the muffler Be sure to clean out both arresters if your model has two Exhaust Outlet 2 Place the transmission in park o Start the engine 4 Quickly squeeze and release the Clean Out Plug throttle lever several times to purge carbon from the system
33. gear selector is located on the right side of the vehicle High Gear Low Gear Neutral Reverse Park To shift gears brake to a complete stop When the engine is idling move the lever to the desired gear NOTICE Shifting gears with the engine speed above idle or while the vehicle is moving could cause transmission damage Always place the transmission in park and lock the parking brake when ever the vehicle is left unattended Belt Life To extend belt life use low forward gear when pulling a heavy load at less than seven miles per hour for extended periods and when operating uphill at a slow speed Fuel Tank Cap Always refuel with the engine stopped and outdoors or in a well ventilated area Refuel on a level surface Gear Selector VEZ Fuel Tank Remove the fuel tank cap to add fuel to the fuel tank Use either leaded or unleaded gasoline with a minimum pump octane number of 87 R M 2 octane Do not use fuel with etha nol content greater than 10 percent such as E 85 fuel 23 FEATURES AND CONTROLS All Wheel Drive AWD System The All Wheel Drive system is controlled by the 4X4 AWD switch ADC 4X4 Mode if equipped When the switch is on ADC 4X4 Emm the ADC system allows engine braking to all six wheels when the Al vehicle descends a hill or incline Always move the 4X4 switch to ks ADC 4X4 before ascending or 4X4 J Switch descending a hill S
34. 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 INTRODUCTION Failure to heed the warnings and safety precautions contained in this manual can result in severe injury or death This POLARIS vehicle is not a toy and can be hazardous to operate This vehicle handles differently than other vehicles such as motorcycles and cars 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 Understand all safety warnings precautions and operating procedures before operating this vehicle Keep this manual with the vehicle Never operate this vehicle without proper instruction Take a training course This vehicle is an ADULT VEHICLE ONLY Operation is prohibited for anyone under 16 years of age Never permit a guest
35. operation on hilly or mountainous terrain ADC is the primary mode of all wheel drive operation Tip If the front gearcase is makes excessive noise during ADC operation change the demand drive fluid If the noise continues please see your POLARIS dealer for service Maintain the fluid level at the bottom of the fill hole threads See below for capacity Demand Drive Capacities Demand Drive with ADC 9 3 oz 275 ml The fill plug is located on the right side of the demand drive unit The drain plug is located on the bottom right side of the unit Fluid Check 1 Position the vehicle on a level surface Remove the fill plug Check the fluid level 2 Add the recommended fluid as needed to bring the level to the bottom of the fill hole threads 3 Reinstall the fill plug Fill Level Drain Plug Torque to 8 10 ft Ibs 11 14 Nm 88 MAINTENANCE Front Gearcase Demand Drive Fluid Fluid Change 1 9o Qv p qe v9 PO Position the vehicle on a level surface Remove the fill plug Place a drain pan under the demand drive unit Remove the drain plug Allow the fluid to drain completely Clean and reinstall the drain plug Torque to 11 ft lbs 15 Nm Add the recommended fluid Reinstall the fill plug Torque to 8 10 ft Ibs 11 14 Nm Check for leaks Dispose of used fluid properly 89 MAINTENANCE Rear Gearcase Oil Always check and change the rear gearcase oil at the i
36. 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
37. tank vent line Inspect and replace Incorrect fuel Replace with recommended fuel Clogged air filter Inspect and clean or replace Reverse speed limiter malfunction See your dealer Throttle release switch malfunction See your dealer Other mechanical failure Possible Lean Fuel Cause Low or contaminated fuel See your dealer Solution Add or change fuel clean the fuel system Kinked or plugged fuel tank vent line Inspect and replace Low octane fuel Replace with recommended fuel Clogged fuel filter Replace filter Incorrect fuel Possible Rich Fuel Cause Fuel is very high octane Replace with recommended fuel Solution Replace with lower octane fuel Stopping starting without adequate warm up Allow engine to warm up before operat ing and or stopping Incorrect fuel Replace with recommended fuel Clogged air filter Inspect and clean or replace 132 TROUBLESHOOTING Engine Stops or Loses Power Possible Cause Solution Out of fuel Refuel cycle key to ON position three times for 5 seconds each then start Kinked or plugged fuel vent line Inspect and replace Water is present in fuel Replace with new fuel Fouled or defective spark plugs Inspect clean and or replace spark plug Worn or defective spark plug wires See your dealer Incorrect spark plug gap or heat range Set gap to specs or
38. to prevent the battery from running low if winching for long periods 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 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 Ibs 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 F Doing this reduces the chances of the winch cable wedging itself between lower layers of winch cable m Jop T3 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 74 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
39. Always inspect your winch cable before each use Inspect for worn or kinked winch cable A 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 damaged Promptly discontinue use of a winch cable in this condition A kinked winch cable made of wire rope that has been ILI PCO RSC EE TTET 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 i 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 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 ener
40. Brake fluid change every two years and any time the fluid looks dark or contaminated Coolant test strength Fog the Engine 1 Treat the fuel system with POLARIS Carbon Clean following the instructions on the can Run the engine for several minutes so the Carbon Clean reaches the injectors Stop the engine Remove the spark plugs 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 Reinstall the spark plugs Torque to specification Apply dielectric grease to the inside of each spark plug cap and rein stall the caps onto the plugs Turn the engine over several times Oil will be forced in and around the piston rings and ring lands coating the cylinder with a protec tive film of fresh oil If POLARIS fuel system additive is not used the fuel tank fuel lines and injectors should be completely drained of gasoline 125 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 79 Battery Maintenance Remove the battery and recharge it as outlined on page 119 Store the battery in a cool dry place Storage Area Covers Set the tire pressure and safely support the vehicle with the tires slightly off the ground Be sure the storage area is well ventilated
41. Cover the vehicle with a genuine POLARIS cover Do not use plastic or coated materials They do not allow enough ventilation to prevent condensa tion and may promote corrosion and oxidation Accessories Auxiliary power outlets provide 12 volt power for operating accesso ries Accessory outlets are available for all models POLARIS also has a wide range of additional accessories available for your vehicle Always install accessories that are approved for use on this vehicle Please see your POLARIS dealer 126 MAINTENANCE Transporting the Vehicle Follow these procedures when transporting the vehicle 1 Stop the engine 2 Place the transmission in park 3 Lock the parking brake 4 Secure the fuel cap oil cap and seat 5 Always tie the frame of the vehicle to the transporting unit securely with suitable straps or rope Do not attach tie straps to the front A arm bolt pockets racks or handlebars 6 Remove the key to prevent loss during transporting 127 MAINTENANCE Camber and Caster The camber and caster are non adjustable Rear Springs The rear shock absorber springs are adjusted by rotating the adjusters either clockwise or counter clockwise to increase or decrease spring tension Always adjust all rear springs to equal settings Accessory springs are available through your POLARIS dealer Handlebars The handlebars can be adjusted for rider preference WARNING
42. Driving on Slippery Surfaces Sideways Turn in skid Y direction of skid C 2eC D C 2C D S7 ONE TLDix lt s lt s fa sc Cec S BS O Q4 J Whenever riding on slippery surfaces such as wet trails or loose gravel or during freezing weather follow these precautions 1 Do not operate on excessively rough slippery or loose terrain 2 Slow down when entering slippery areas 3 Engage 4X4 before wheels begin to lose traction NOTICE Severe damage to drive train may occur if the 4X4 is engaged while the wheels are spinning Allow the rear wheels to stop spinning before engaging 4X4 or engage 4X4 before wheels begin to lose traction 4 Maintain a high level of alertness reading the trail and avoiding quick sharp turns which can cause skids 5 Never apply the brakes during a skid Correct a skid by turning the handlebars in the direction of the skid and shifting your body weight forward 54 OPERATION Driving Uphill 25 Maximum Braking and handling are greatly affected when operating in hilly ter rain Improper procedure could cause loss of control or overturn When ever traveling uphill follow these precautions 1 Always move the 4X4 switch to ADC 4X4 if equipped before ascending or descending a hill See page 36 Drive straight uphill Avoid steep hills 25 maximum Always check the terrain carefully before ascending any hill Never climb hills with excessively slippery or loose s
43. E INJURY or DEATH See the Shock Loading section on page 75 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 70 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 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 Before operating the winch be sure that the safety latch on the winch cable hook is fully seated when the load is attached Never operate your winch with a damaged hook or latch Always replace damaged parts before using the winch YES NO WINCH GUIDE Winch Operation S 6 7 10 Never remove the hook strap from the hook Release the winch clutch and pull out the winch cable 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
44. FETY Safety Warnings Descending Hills Improperly Improperly descending a hill could cause loss of control or overturn Always follow proper procedures for travel ing down hills as described in the owner s manual NOTE A special technique is required when braking while traveling down hill See page 57 Always descend a hill with the transmission in forward gear Do not descend a hill with the transmission in neutral Always move the 4X4 switch to ADC 4X4 if equipped before ascending or descending a hill See page 36 Always check the terrain carefully before descending a hill Shift your weight rearward Never travel down a hill at high speed Avoid traveling down a hill at an angle which would cause the vehicle to lean sharply to one side Travel straight down the hill when possible Crossing Hillsides Driving on a sidehill is not recommended Improper procedure could cause loss of control or overturn Avoid crossing the side of any hill unless absolutely necessary If crossing a hillside is unavoidable always follow proper procedures as described in the owner s manual See page 56 Never attempt to turn the vehicle around on any hill until you ve mastered the turning technique on level ground as described in the owner s manual See page 58 15 SAFETY Safety Warnings Stalling While Climbing a Hill Stalling rolling backwards or improperly dismounting while climbing a hill could cause an overtu
45. POLARIS Sportsman Forest 800 6X6 Owner s Manual for Maintenance and Safety Read this manual carefully It contains important safety information This is an adult vehicle only Operation is prohibited for those under 16 years of age 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 e Snowmobiles All terrain vehicles ATVs Low emission vehicles LEVs e RANGERQ utility vehicles e RZR sport vehicles VICTORY motorcycles GEMQ vehicles Always follow the instructions and recommendations in this manual The manual contains instructions for minor maintenance but information about major repairs is outlined in the POLARIS Service Manual and should be performed only by a factory certified Master Service Dealer MSD technician Please see your dealer for all of your service needs during and after the warranty period POLARIS POLARIS and SPORTSMANQ are registered trademarks of POLARIS Industries Inc Copyright 2013 POLARIS Sales 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 productio
46. and slide it over the cable adjuster to its original position b Boot Lock Nut Adjuster 129 TROUBLESHOOTING Drive Belt Wear Burn Possible Cause Solution Driving onto a pickup or tall trailer in high range Use low range during loading Starting out going up a steep incline Use low range or turn around using the K turn see page 58 Driving at low RPM or ground speed 3 7 MPH Drive at a higher speed or use low range more frequently See page 114 Insufficient warm up at low ambient tempera tures 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 flex ible and prevent belt burning Slow easy clutch engage ment Use the throttle quickly and effectively Towing pushing at low RPM low ground speed Use low range only Utility use plowing Use low range only Stuck in mud or snow 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 overturn Climbing over large objects from a stopped position 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 overturn Belt slippage from water or snow
47. ause 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 A 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 identi fied 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 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 termi nals with dielectric grease or petroleum jelly Be careful not to allow cleaning solution or tap water into a conventional battery
48. cable while winching a load Never let the winch cable run through your hands even if wearing heavy gloves Never release the clutch on the winch Ri when the winch cable is under load Never use the winch for lifting or transporting people 67 WINCH GUIDE Winch Safety Precautions 20 21 22 23 24 25 68 Never use the winch to hoist or suspend a vertical load Never immerse or submerse your winch in water Take your winch to your dealer for service if this occurs Always inspect your winch and winch cable before each use Never winch the hook fully into the winch This can cause damage to winch components Unplug the remote control from the vehicle when the winch is not in use to prevent inadvertent activation and use by unauthorized persons Never grease or oil the winch cable This will cause the winch cable to collect debris that will shorten the life of the cable 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 A 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 w
49. 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 Secure the battery hold down strap 9e c Qv A Verify that cables are properly routed Cables should be safely tucked away at the front and rear of the battery 117 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 POLARIS recommends maintaining battery charge by using a POLARIS Battery Tender charger or by charging about once a month to make up for normal self discharge Battery Tender can be left connected during the storage period and will automatically charge the battery if the voltage drops below a pre determined point See page 136 for the part numbers of POLARIS products Battery Fluid Conventional Battery A poorly maintained battery will deteriorate rapidly Check the battery resa er 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 118 MAINTENANCE Battery Battery Charging Conventional Battery 1 Remove the battery from the vehicle to prevent
50. 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 46 OPERATION Break In Period Engine and Drivetrain Break in 1 Fill the fuel tank with gasoline See page 33 Always exercise extreme caution whenever handling gasoline 2 Check the engine oil level on the dipstick See page 84 Add oil if necessary to maintain the level between the safe and add marks 3 Drive slowly at first Select an open area that allows room to famil iarize yourself with vehicle operation and handling 4 Vary the throttle positions Do not operate at sustained idle 5 Perform regular checks on fluid levels controls and areas outlined on the daily pre ride inspection checklist See page 48 6 Pull only light loads Change both the oil and the filter at 25 hours Check fluid levels of transmission and all gearcases after the first 25 hours of operation and every 100 hours thereafter PVT Break in Clutches Belt A proper break in of the clutches and drive belt will ensure a longer life and better performance Break in the clutches and belt by operating at slower speeds during the break in period as recommended Pull only light loads Avoid aggressive acceleration and high speed operation dur ing the break in period If a belt fails always clean away all debris when replacing the belt 47 OPERATION Pre Ride C
51. e winch cable in an attempt to move a second stuck vehicle See the Shock Loading section on page 75 For your safety always follow these guidelines when winching a vehicle free IO J K mmo Q0 p gt Release the winch clutch and spool out the necessary length of winch cable Align the winch cable as close as possible to the winching vehicle s centerline Attach the winch cable hook to the anchor point or the stuck vehicle s frame following instructions in this manual Re engage the clutch on the winch Slowly winch in the slack in the winch cable Select the proper vehicle gear to propel the stuck vehicle in the direction of winching Shift to the lowest gear available on the stuck vehicle Slowly and carefully apply vehicle throttle and winch together to free the vehicle Stop winching as soon as the stuck vehicle is able to propel itself without the help of the winch Detach the winch cable hook 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 T2 WINCH GUIDE Winch Operation 13 Extensive winching will run down the battery on the winching vehicle Let the winching vehicle s engine run while operating the winch
52. e descends a hill or incline Always move the 4X4 switch to ADC 4X4 before ascending or descending a hill Engaging Active Descent Control The ADC system will automatically engage when all four of the follow ing conditions occur The 4X4 switch must be in the ADC 4X4 position Vehicle speed must be 15 MPH 24 km h or less The throttle must be closed throttle lever released The transmission must be in gear high low or reverse Disengaging Active Descent Control The ADC system will automatically disengage if at least one of the fol lowing conditions occur The 4X4 switch is moved out of the ADC 4X4 position Vehicle speed exceeds 15 MPH 24 km h The throttle is open throttle is applied The transmission is shifted to neutral or park 36 FEATURES AND CONTROLS Instrument Cluster Your vehicle is equipped with an instrument cluster that senses vehicle speed from the right front wheel In addition to showing vehicle speed the speedometer needle flashes when a warning condition exists The instrument cluster measures distance in miles as well as hours of operation It also includes a reverse speed limiter function that limits the vehicle s speed to approximately 7 9 MPH 11 14 km h Refer to page 26 for additional information Speedometer Needle Speedometer uy 20 39 Rider I2 AN m1 I Information Center NOTICE High water pressure may damage vehicle components Wash the vehicle b
53. e page 136 for the part numbers of POLARIS products The middle gearcase fill plug is located on the side of the gearcase Maintain the oil level even with the bottom thread of the fill plug hole Cil Check MAINTENANCE Drain Plug Check Fill Plug 1 Position the vehicle on a level surface 2 Remove the fill plug Check the oil level 3 Add the recommended oil as needed 4 Reinstall the fill plug Torque to 14 ft Ibs 19 Nm Oil Change 1 Remove the fill plug 2 Remove the drain plug from the bottom of the gearcase Drain the oil into a drain pan Discard used oil properly Qv UC ope Check for leaks Clean and reinstall the drain plug Torque to 14 ft Ibs 19 Nm Add 17 oz 500 ml the recommended fluid Reinstall the fill plug Torque to 14 ft Ibs 19 Nm 91 MAINTENANCE Active Descent Control ADC Fluid If your vehicle is equipped with Active Descent Control there are two fluid levels that must be maintained demand drive fluid and ADC fluid See page 88 for demand drive fluid maintenance Check and change the ADC fluid level at the intervals outlined in the Periodic Maintenance Chart beginning on page 79 Maintain the fluid level between the minimum and maximum marks on the reservoir We recommend the use of POLARIS Demand Drive Fluid See page 136 for the part numbers of POLARIS products NOTICE Do not use brake fluid Brake fluid will damag
54. e route Operators assume all risk associated with ice conditions on frozen bodies of water 20 SAFETY Safety Warnings Operating a Damaged Vehicle Operating a damaged vehicle can result in an accident After any overturn or accident have a qualified service dealer inspect the entire machine for possible damage including but not limited to brakes throttle and steering systems Physical Skills Safe operation of this rider active vehicle requires good judgement and physical skills Persons with cognitive or physical disabilities who operate this vehicle have an increased risk of overturn and loss of control 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 Unauthorized Use of the Vehicle Leaving the keys in the ignition can lead to unauthorized use of the vehicle which could result in an accident or overturn Always remove the ignition key when the vehicle is not in use 21 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 i
55. e rubber components in the hydraulic system 1 Open the front box cover 2 Remove the access panel screws Squeeze the outer edges of the panel inward to remove the panel 3 View the fluid level in the reser voir 4 Ifthe level is below the minimum mark remove the cap and add the recommended fluid 5 Reinstall the cap 6 Reinstall the access panel and secure the front box cover ADC Fluid Reservoir 92 MAINTENANCE Active Descent Control ADC Fluid Fluid Change 1 2 rd Position the vehicle on a level surface Before performing the fluid change allow the vehicle to sit for at least 30 minutes Thoroughly clean the areas around and on the ADC reservoir and bleeder valves one on each side of the differential Remove the reservoir cap and diaphragm assembly Use a shop towel or suction tool to remove debris from the fluid and reservoir Debris in the reservoir may result in inadequate bleeding and reduced performance of the system Fill the reservoir to the maximum line with fresh fluid Remove the protective caps from the bleeder valves Slowly loosen one of the bleeder valve screws turn counter clock wise and allow fluid and trapped air to flow from the fitting Tighten the screw when clean fluid begins to flow Repeat this step for the remaining valve IMPORTANT Close the bleeder valve screws before the reservoir fluid level drops below the minimum fill line Adding fluid to an empty
56. e 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 Reduce speed and allow a greater distance for braking Cargo should be properly distributed and carried as low and forward in the cargo box as possible Always attach the tow load to the hitch point designated for your vehicle Use extreme caution when applying brakes with a loaded vehicle Avoid terrain or situations that may require backing downhill Do not block the front headlight beam when carrying loads on the front rack Do not tow any trailer on a grade steeper than 15 NEVER exceed 50 MPH 80 km h when rear cargo loads are above 75 lbs 34 kg and or front cargo loads are above 37 lbs 17 kg NEVER exceed 10 MPH 16 km h when rear cargo loads are above 200 lbs 91 kg and or front cargo loads are above 100 Ibs 45 kg Vehicle should never exceed 10 MPH 16 km h while towing a load on a level 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 Maximum Cargo Capacities Level Ground Total Cargo 900 Ibs 408 kg Front Rack Cargo 100 Ibs 45 kg Cargo Box 800 Ibs 363 kg 62 OPERATION Hauling Cargo Load cargo as far forward as possible 1 Always read and u
57. ealer 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 amp Canada 1 800 POLARIS 1 800 765 2747 French 1 800 268 6334 140 MAINTENANCE LOG Present this section of your manual to your dealer each time your vehicle is serviced This will provide you and future owners with an accurate log of maintenance and ser vices performed DATE MILES KM OR HOURS TECHNICIAN SERVICE PERFORMED COMMENTS 141 MAINTENANCE LOG DATE MILES KM OR HOURS TECHNICIAN SERVICE PERFORMED COMMENTS 142 0 9 4x4 Switch 00055 34 A Accessories cis ars Gd Byala 44 126 Active Descent Control Fluid 92 93 Active Descent Control System 36 ADC SYSE rsen 36 Air Filter ies ev eh nme 101 All Wheel Drive AWD System 34 35 AWD Switch 26 B Battery cc eee wees 115 120 Charging Conventional 119 Charging Sealed 120 Charging Sealed
58. ed for additional lubrication at the user s discretion Item Lube Method Engine Oil PS 4 5W 50 4 Cycle Oil See page 84 Brake Fluid DOT 4 Brake Fluid See page 31 Transmission Oil AGL Gearcase Lubricant amp See page 87 Transmission Fluid Demand Drive Fluid Demand Drive Fluid See page 88 Front Gearcase Middle Gearcase Oil ATV Angle Drive Fluid or See page 91 GL5 80 90 weight gear lube Rear Gearcase Oil See page 90 ADC Fluid Demand Drive Fluid See page 92 Front Prop Shaft Yoke U Joint Grease Grease fittings 3 pumps maxi mum every 500 miles before long periods of storage or after pres sure washing or submerging Front Prop Shaft Yoke 83 MAINTENANCE Engine Oil Oil Recommendations POLARIS recommends the use of POLARIS PS 4 Full Synthetic 5W 50 4 cycle oil or a similar oil for this engine Oil may need to be changed more frequently if POLARIS oil is not used Always use 5W 50 oil Follow the manufacturer s recommendations for ambient temperature operation See page 136 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 Cil Level Access the oil dipstick and fill tube Dipstick from the left side of the vehicle 1 Position the vehicle on a level surface 2 Lift the lever lock to remove the dipstick
59. ee page 36 AWD Mode When the switch is on 4X4 the vehicle is in all wheel drive and the AWD indicator light in the instrument cluster will be on When in AWD the demand drive unit will automatically engage any time the rear wheels lose traction When the rear wheels regain traction the demand drive unit will automatically disengage There is no limit to the length of time the vehicle may remain in AWD 2X4 Mode When the switch is on 2X4 the middle and rear wheels drive at all times 34 FEATURES AND CONTROLS All Wheel Drive System Engaging AWD The 4X4 switch may be turned on or off while the vehicle is moving Initially the vehicle s electronic system will not enable AWD until the engine RPM is below 3100 Once enabled AWD remains enabled until the 4X4 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 4X4 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 4X4 or ADC 4X4 while the rear wheels are spinning may cause severe drive shaft and gearcase damage Always switch to 4X4 or ADC 4X4 while the rear wheels have traction or are at rest 35 FEATURES AND CONTROLS Active Descent Control ADC System The ADC system if equipped allows engine braking to all four wheels when the vehicl
60. erator s risk of losing control Always operate at a speed that s appropriate for the terrain the visibility and operating conditions and your experience SAFETY 13 SAFETY Safety Warnings Physical Control of the Vehicle Removing a hand from the handlebars or feet from the footrests during operation can reduce your ability to control the vehicle or cause loss of balance and ejection from the vehicle If the operator s foot is not firmly planted on the footrest it could also contact the rear wheels Never remove your hands from the handlebars while operating and always keep both feet on the footrests Turning Improperly Turning improperly could cause loss of traction loss of control accident or overturn Always follow proper procedures for turning as described in the owner s manual Never turn abruptly or at sharp angles Never turn at high speeds Practice turning at slow speeds before attempting to turn at faster speeds Jumps and Stunts Attempting wheelies jumps and other stunts increases the risk of an accident or overturn Never attempt wheelies jumps or other stunts Avoid exhibition driving Improper Hill Climbing Improper hill climbing could cause loss of control or overturn Always follow proper procedures for climbing hills as described in the owner s manual See page 55 Always move the 4X4 switch to ADC 4X4 if equipped before ascending or descending a hill 14 SA
61. erride Switch 26 Rider Information Center 38 45 Riding Area 50 Riding Gear i5 cnr 58 cen 8 9 S Safe Operation Practices 49 Safety Labels 22 25 Safety Training 7 Safety Warnings 11 21 Safety Winch Maintenance TI Service Interval Programming 42 Severe Use ies lese RE XE 79 Shock Loading the Winch 75 16 Side Panel Removal 98 Sidehilling ode etre ce 56 Signal Words 2 26 86 es cee cous 4 Spark Arrester 111 Spark Plug Inspection 108 109 Spark Plug Recommendations 108 Spark Plug Torque Specification 108 Spark Plugs 108 109 Specifications 800 EFI 135 Spring Adjustment Rear Shock 128 Starting the Engine 51 Steering Assembly 98 SOALE 2 vsceciceke ur cea ete 121 126 Storage Tips 124 126 S Switches AWD Switch 26 34 Engine Stop Switch 27 Headlight Switch 27 Main Key Switch 27 Mode Switch 26 Reverse Override Switch 26 Stop Switch ioo bere 27 Winch Switch 26 T Taillightz sitet ceps 107 Throttle Body Adjustment 129 Throttle Cable Freeplay Adjustment 129 Throttle Lever 28 Tire Tread Depth eis eee a ane 99 Tiresz 2 mrt 99 100 Wheel Installation 100 Wheel Nut Torque
62. erturn or accident have a qualified service dealer inspect the entire machine for possi ble damage Never operate the vehicle on a frozen body of water unless you have independently 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 Do not touch hot exhaust system components Always keep com bustible materials away from the exhaust system Always remove the ignition key when the vehicle is not in use to prevent unauthorized use 49 OPERATION Know Your Riding Area Tread Lightly Familiarize yourself with all laws and regulations concerning the opera tion of this off road vehicle in your area Respect the environment in which you ride Find out where the designated riding areas are by con tacting 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 vehi cles in your group When stopping move your vehicle to the edge o
63. ery voltage Recharge the battery to 12 8 VDC Mechanical failure See your dealer Engine Backfires Possible Cause Weak spark from spark plug Solution Inspect clean and or replace spark plugs Incorrect spark plug gap or heat range Set gap to specs or replace plugs Old or non recommended fuel Replace with fresh recommended fuel Incorrectly installed spark plug wires See your dealer Incorrect ignition timing See your dealer Mechanical failure See your dealer Loose ignition connections Check all connections and tighten Water present in fuel Replace with fresh recommended fuel 131 TROUBLESHOOTING Engine Pings or Knocks Possible Cause Poor quality or low octane fuel Solution Replace with recommended fuel Incorrect ignition timing See your dealer Incorrect spark plug gap or heat range Set gap to specs or replace plugs Engine Runs Irregularly Stalls or Misfires Possible Cause Fouled or defective spark plugs Solution Inspect clean and or replace spark plugs Worn or defective spark plug wires See your dealer Incorrect spark plug gap or heat range Set gap to specs or replace plugs Loose ignition connections Check all connections and tighten Water present in fuel Replace with new fuel Low battery voltage Recharge battery to 12 8 VDC Kinked or plugged fuel
64. est way to clean your POLARIS vehicle is with a gar den hose and a pail of mild soap and water 1 Useaprofessional 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 121 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 decals Avoid directing the water stream at the follow ing items Wheel bearings Hlectrical components e Radiator Switches and controls Transmission seals Fuel system components Cab and body panels Labels and decals If an informational or graphic label becomes illegible or comes off con tact your POLARIS dealer to purchase a replacement Replacement safety labels are provided by POLARIS at no charge 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
65. f 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 See page 42 The service interval is programmed at 50 hours at the factory 41 FEATURES AND CONTROLS Instrument Cluster Rider Information Center Diagnostic Mode Programmable service interval To enable or disable the service interval 1 2 3 Enter the diagnostic mode Toggle to the service interval screen Press and hold the mode button for about 7 seconds until either ON or OFF appears in the Rider Information Center depending on your preference To reset the service interval 1 2 3i Enter the diagnostic mode Toggle to the service interval screen Press and hold the mode button for 2 3 seconds until the wrench icon flashes Release the button Press and release the mode button once to advance the setting by one hour Press and hold the mode button to advance the hours quickly If you scroll past the intended number press and hold the button until the hours cycle back to zero When the desired setting is displayed wait until the wrench icon stops flashing The new service interval is now programmed Miles Kilometers toggle The display in the tripmeter and odometer can be changed to display either standard or metric units of measurement 2 42 Enter the d
66. f the trail as far as possible to allow others to pass safely 50 OPERATION Starting the Engine Position the vehicle on a level surface outdoors or in a well venti lated area 2 Place the transmission in park 3 Lock the parking brake Tip The starter interlock will prevent the engine from starting if the transmission is in gear and the brake is not engaged 4 Siton the vehicle and move the engine stop switch to RUN 5 Do not press the throttle while starting the engine 6 Turn the ignition key past the ON position to engage the starter Activate the starter for a maximum of five seconds releasing the key when the engine starts 7 Ifthe engine does not start return the key to the OFF position and wait five seconds before attempting to start again Activate the starter for another five seconds if necessary Repeat this procedure until the engine starts NOTICE Operating the vehicle immediately 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 accu mulation increases as outside temperature decreases See your POLARIS dealer for engine heater k
67. faces 18 Safety Warnings Improper Cargo Loading Overloading the vehicle or carrying towing cargo improperly may cause changes in handling which could cause loss of control or an accident Never exceed the stated load capacity for this vehicle Cargo should be properly distributed and securely attached Reduce speed when carrying cargo or pull ing a trailer Allow a greater distance for braking NEVER exceed 50 MPH 80 km h when rear cargo loads are above 75 Ibs 34 kg and or front cargo loads are above 37 Ibs 17 kg NEVER exceed 10 MPH 16 km h when rear cargo loads are above 200 lbs 91 kg and or front cargo loads are above 100 Ibs 45 kg Always follow the instructions in the owner s manual for carrying cargo or pull ing a trailer See pages 62 64 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 61 Before shifting into reverse gear always check for obstacles or people behind the vehicle When it s safe to proceed back slowly Poor Visibility Operating the 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 v
68. g conditions will release all of the stored energy This will increase the chances of SEVERE INJURY or DEATH 77 EMISSION CONTROL SYSTEMS Noise Emission Control System Do not modify the engine intake or exhaust components as doing so may affect compliance with governmental noise level requirements Exhaust Emission Control System Exhaust emissions are controlled by engine design An electronic fuel injection EFI system controls fuel delivery The engine and EFI com ponents are set at the factory for optimal performance and are not adjustable Electromagnetic Interference This vehicle complies with the EMC requirements of European direc tives 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 lim itations of their device and the applicable electromagnetic standards and directives that apply to this vehicle European Vibration and Noise The driver perceived noise and hand arm and whole body vibration lev els 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 con trolled as indicated by the test procedure s The uncertainty of vibration exposure measurement is dependent on many factors including nstrument and calibration unce
69. gh slippery or loose terrain Always use extra caution on rough slippery or loose terrain Operating in Unfamiliar Terrain Failure to use extra caution when operating on unfamiliar terrain could result in an accident or overturn Unfamiliar terrain may contain hidden rocks bumps or holes that could cause loss of control or overturn Travel slowly and use extra caution when operating on unfamiliar terrain Always be alert to changing terrain conditions 17 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 Over Obstacles Improperly operating over obstacles could cause loss of control or overturn Before operating in a new area check for obstacles Avoid operating over large obstacles such as rocks and fallen trees If unavoidable use extreme caution and always follow proper operating procedures as outlined in this manual See page 60 Skidding or Sliding Skidding or sliding can cause loss of control or overturn if tires regain traction unexpectedly On slippery surfaces such as ice or loose gravel travel slowly and use extra caution to reduce the chance of skidding or sliding Do not operate on excessively slippery sur
70. gy This is true of both wire rope and synthetic rope winch cables p 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 gener ates 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 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 75 WINCH GUIDE Shock Loading 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 ca
71. he spark plug cap 1 4 turn and pull it off the spark plug 2 Using the special wrench provided in the tool pouch rotate the spark plug counter clockwise to remove it 3 Reverse the procedure for spark plug installation Torque to specifi cation 108 MAINTENANCE Spark Plugs Spark Plug Inspection Normal Spark Plug The normal insulator tip is gray tan or light brown There will be few combustion deposits The electrodes are not burned or eroded This indi cates the proper type and heat range for the engine and the service The tip should not be flaky and white A white insulator tip indicates overheating caused by use of an improper spark plug or incorrect fuel Wet Fouled Spark Plug The wet fouled 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 excessive oil use of non recommended oil or incorrect throttle body adjustments 109 MAINTENANCE Vehicle Immersion If your vehicle becomes immersed major engine damage can result if the machine is not thoroughly inspected Take the vehicle to your dealer before starting the engine If it s impossible to take your vehicle to a dealer before starting it follow the steps outlined below 110 Move the vehicle to dry land or at the very least to water below the footrests Check the air box If water is present dry the air box and replace the
72. hecklist Failure to inspect and verify that the vehicle is in safe operating condi tion 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 Remarks Page Brake system lever travel Ensure proper operation F Brake fluid Ensure proper level 31 Auxiliary brake Ensure proper operation 30 ADC Fluid Ensure proper level 92 Front suspension Inspect lubricate if necessary 83 Rear suspension Inspect lubricate if necessary 83 Steering Ensure free operation Tires Inspect condition and pressure 99 Wheels fasteners Inspect ensure fastener tightness p Frame nuts bolts fasteners Inspect ensure tightness Fuel and oil Ensure proper levels a Coolant level if applicable Ensure proper level Be Coolant hoses if applicable Inspect for leaks Throttle Ensure proper operation a Indicator lights switches Ensure operation 26 Engine stop switch Ensure proper operation 27 Air filter pre filter Inspect clean 101 Air box sediment tube Drain deposits whenever visible Headlamp Check operation apply POLARIS 27 dielectric grease when lamp is 103 replaced Brake light tail lamp Check operation apply POLARIS 107 dielectric grease when lamp is replaced Dump box latch Check condition and operation of the mechanism Riding gear Wear approved helmet goggles and 8 protective cloth
73. hrottle Cable 50 H 6M 310 500 Inspect adjust lubricate Throttle Release replace if necessary Switch Throttle Body 50 H 6M 310 500 Inspect duct for proper Intake Duct sealing air leaks gt Front hub bearings 50 H 6M 310 500 Inspect clean replace as if equipped needed Drive belt 50 H 6M 310 500 Inspect adjust replace as needed Cooling system 50 H 6M 310 500 Inspect coolant strength if applicable seasonally pressure test system yearly 81 MAINTENANCE Periodic Maintenance Chart Item Maintenance Interval Remarks whichever comes first Hours Calendar Miles Km gt Oil lines and 100 H 6M 1000 1600 Inspect for leaks and loose fasteners fittings gt Engine oil change 100 H 6M 1000 1600 Change the oil and filter gt Demand drive fluid 100 H 12M 1000 1600 Change fluid normal use gt Middle gearcase 100 H 12M 1000 1600 Change fluid oil 6x6 gt Rear gearcase oil 100 H 12M 1000 1600 Change fluid gt Transmission oil 100 H 12M 1000 1600 Change fluid Fuel system 100 H 12M 620 1000 Check for leaks at tank cap lines filter pump replace lines every two years gt Radiator 100 H 12M 620 1000 Inspect clean external surfaces gt Cooling hoses 100 H 12M 620 1000 Inspect for leaks gt Engine mounts 100 H 12M 620 1000 Inspect Exhaust muffler 100 H 12M 620 1000 I
74. iagnostic mode Toggle to the screen that displays either kilometers KM or miles MP Press and hold the mode button until the letters flash then press and release the button once When the display stops flashing the mode has been set FEATURES AND CONTROLS Instrument Cluster Rider Information Center Downloading Codes The EFI diagnostic mode is for informational purposes only Please see your POLARIS dealer for all major repairs See page 45 for Blink Codes and Failure Descriptions Use the follow ing procedure to download blink codes failure codes from the EFI module 1 2 3 4 Place the transmission in park Stop the engine Turn the key switch to the ON position Turn the key switch off and on three times in less than five seconds then leave the switch on Any blink code numbers stored in the EFI module will display one at a time on the screen The number 61 and the word END displays after all codes have been transmitted 43 FEATURES AND CONTROLS Instrument Cluster Rider Information Center Downloading Codes 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 i
75. inching 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 lift ing 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 winching Use wheel chocks if needed Hook Strap Pd EM ud Ca 69 WINCH GUIDE Winch Operation 4 Always use the hook strap when INJURY A handling the hook WARNING Never put your fingers into the hook This could lead to SEVERE Attach the hook itself onto the NO YES load or use a tow strap or chain to secure the load to the winch cable Tip A tow strap is NOT intended to stretch A recovery strap is designed to stretch 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 SEVER
76. ing Winch Inspect cable and switch 74 77 48 OPERATION Safe Operation Practices 1 2 10 11 12 13 14 Complete the recommended safety training before operating this vehicle See page 7 Do not allow anyone under 16 years of age to operate this vehicle Do not allow anyone with cognitive or physical disabilities to oper ate this vehicle Never carry a passenger on this vehicle Engine exhaust fumes are poisonous Never start the engine or let it run in an enclosed area Before operating learn how to use the auxiliary brake for emer gency situations if service brakes become inoperable Operate this vehicle off road only Never operate the vehicle on pavement or on any public street road or highway including dirt and gravel roads Use caution and drive at reduced speeds in conditions of reduced visibility such as fog rain and darkness Clean headlights fre quently and replace burned out headlamps promptly Drive in a manner appropriate for your skills and operating condi tions Never operate at excessive speeds Never attempt wheelies jumps or other stunts Never remove your hands from the handle bars while operating and always keep both feet on the footrests Never consume alcohol or drugs before or while operating this vehi cle Always use the size and type of tires specified for your vehicle Always maintain proper tire pressure Never operate a damaged vehicle After any ov
77. ing but not limited to mow ers blades tires sprayers or large racks may change the handling char acteristics of the vehicle Use only POLARIS approved accessories and familiarize yourself with their function and effect on the vehicle SAFETY Failure to operate the vehicle properly can result in a collision loss of control accident or overturn which may result in serious injury or death Heed all safety warnings outlined in this section of the owner s manual 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 Never operate this vehicle without proper instruction Take a training course Beginners should receive training from a certified instructor Never permit others to operate the vehicle unless they have read and understand this manual and all product labels and have completed a certified safety training course Age Restrictions This vehicle is an ADULT VEHICLE ONLY Operation is prohibited for anyone under 16 years of age Even though a child may be within the recommended age group for operating some POLARIS vehicles he she may not have the skills abilities or judgment needed to operate this vehicle safely and could be susceptible to accident or
78. ingestion into the PVT system Dry out the PVT See page 114 Inspect clutch seals for damage if repeated leaking occurs Clutch malfunction See your POLARIS dealer Poor engine performance Check for fouled plugs or foreign material in gas tank or fuel lines See your dealer Slippage from failure to warm up belt Always warm up the belt by operating below 30 MPH for one mile 5 miles or more when temperature is below freezing Wrong or missing belt Install the recommended belt Improper break in Always break in a new belt and or clutch See page 47 130 Engine Doesn t Turn Over Possible Cause Low battery voltage TROUBLESHOOTING Solution Recharge the battery to 12 8 VDC Loose battery connections Check all connections and tighten Loose solenoid connections Check all connections and tighten Engine Turns Over Fails to Start Possible Cause Solution Out of fuel Refuel cycle key to ON position three times for 5 seconds each then start Clogged fuel filter Replace the filter Water is present in fuel Drain the fuel system and refuel Old or non recommended fuel Replace with fresh recommended fuel Fouled or defective spark plugs Inspect plugs and replace if necessary No spark to spark plug Inspect plugs verify stop switch is on Water or fuel in crankcase Immediately see your POLARIS dealer Low batt
79. injury 10 SAFETY Safety Warnings Handling Gasoline Gasoline is highly flammable and explosive under certain conditions Always exercise extreme caution whenever handling gasoline Always refuel with the engine stopped and outdoors or in a well ventilated area Do not smoke or allow open flames or sparks in or near the area where refu eling is performed or where gasoline is stored Do not overfill the tank Do not fill the tank neck f gasoline spills on your skin or clothing immediately wash it off with soap and water and change clothing Exposure to Exhaust Engine exhaust fumes are poisonous and can cause loss of consciousness or death in a short time Never start the engine or let it run in an enclosed area The engine exhaust from this product contains chemicals known to cause cancer birth defects or other reproductive harm Operate this vehicle only outdoors or in well ventilated areas 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 inspect the vehicle before each use to make sure it s in safe operating condition Always follow all inspection and maintenance procedures and schedules described in the owner s manual 11 SAFETY Safety Warnings Protective Apparel Riding on this vehicle without wearing an approved helmet and protective eyewear increases the risk of a ser
80. ious injuries in the event of an accident Operator and passenger must always wear an approved helmet that fits properly and eye protection goggles or face shield Using Alcohol or Drugs Operating the 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 Carrying a Passenger Carrying a passenger greatly reduces the operator s ability to balance and control the vehicle which may result in an accident or overturn Never carry a passenger on this vehicle 12 Safety Warnings Operating on Pavement Operating this vehicle on paved surfaces including sidewalks paths parking lots and driveways may adversely affect the handling of the vehicle and could result in loss of control and accident or overturn Avoid operating the vehicle on pavement The tires are designed for off road use If it s unavoidable travel slowly and avoid sudden turns or stops Operating on Public Roads Operating this vehicle on public streets roads or highways could result in a collision with another vehicle Never operate the vehicle on any public street road or highway including dirt and gravel roads In many regions it s unlawful to operate this type of vehicle on public streets roads and highways Operating at Excessive Speeds Operating the vehicle at excessive speeds increases the op
81. isibility such as fog rain and darkness Clean headlights frequently and replace burned out headlamps promptly 19 SAFETY Safety Warnings Operating Through Deep Water Operating the vehicle through deep or fast flowing water could cause the tires to float causing loss of control or overturn Avoid operating the vehicle through deep or fast flowing water If it s unavoidable to enter water that exceeds the recommended maximum depth see page 59 Travel slowly Balance your weight carefully Avoid sudden movements Maintain a slow and steady forward motion Do not make sudden turns or stops and do not make sudden throttle changes 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 Operating on frozen bodies of water may result in serious injury or death if the vehicle and or the operator fall through the ice Never operate the vehicle on a frozen body of water unless you have independently 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 vehi cles in your party Variances in snow depth and or water currents may result in uneven ice thickness Always check with local authorities and residents to confirm ice conditions and thickness over your entir
82. its which provide quicker warm ups and easier starting in colder weather 51 OPERATION Driving Procedures N Be ae 9 52 Wear a helmet and eye protection See page 8 Sit upright with both feet on the footrests and both hands on the handlebars Start the engine and allow it to warm up Shift the transmission into gear Check your surroundings and determine your path of travel Release the parking brake Slowly depress the throttle with your right thumb and begin driving Drive slowly Practice maneuvering and using the throttle and brakes on level surfaces 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 turn ing and the inside tire must slip traction slightly To turn steer in the direction of the turn leaning your upper body to the inside of the turn while supporting your weight on the outer footrest This technique alters the balance of traction between the rear wheels allowing the turn to be made smoothly The same leaning technique should be used for turning in reverse Practice making turns at slow speeds before attempting to turn at faster speeds WARNING Turning improperly can result in vehicle overturn Never turn abruptly or at sharp angles Never turn at high speeds 53 OPERATION
83. l during cold weather can indicate contaminants collecting in the oil sump or crank case Change oil immediately if the oil level begins to rise Monitor the oll level and if it continues to rise discontinue use and determine the cause or see your dealer 79 MAINTENANCE Periodic Maintenance Chart Maintenance Chart Key Symbol Description Perform these operations more often for vehicles subjected to severe use D Have an authorized POLARIS dealer 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 perform these services Perform all services at whichever maintenance interval is reached first Item Maintenance Interval Remarks whichever comes first Hours Calendar Miles Km Steering Front suspension Rear suspension Tires Make adjustments as need Brake fluid level Pre Ride ed See Pre Ride Checklist Brake lever travel on page 48 Brake system Wheels fasteners Frame fasteners Engine oil level Winch See pages 74 and 77 gt Air filter pre filter Daily Inspect clean often replace as needed gt Air box sediment 7 Daily Drain deposits when visible tube Coolant Daily Check level daily change if applicable co
84. me Duty Synthetic 10W 50 4 Cycle Oil qt 95 I 2878919 PS 4 Extreme Duty Synthetic 10W 50 4 Cycle Oil gal 3 8 1 Gearcase Transmission Lubricants 2878068 RA Synthetic Gearcase Lubricant amp Transmission Fluid 2878069 a Gearcase Lubricant amp Transmission Fluid gal 3 2877922 Demand Drive Fluid qt 95 1 2877923 Demand Drive Fluid gal 3 8 I 2870465 Pump for Gallon 3 8 I Jug Coolant 2871534 Polaris Antifreeze 60 40 Premix qt 95 I 2871323 Polaris Antifreeze 60 40 Premix gal 3 8 1 Grease Specialized Lubricants 2871312 Grease Gun Kit All Season Grease 2871322 All Season Grease 3 0z 89 ml cartridge 2871423 All Season Grease 14 0z 414 ml cartridge 2876160 ATV Angle Drive Fluid qt 95 I 2872276 ATV Angle Drive Fluid 2 5 gal 9 5 I 2871460 Premium Starter Grease 2871515 U Joint Grease 3 0z 89 ml cartridge 2871551 U Joint Grease 14 0z 414 ml cartridge 2871329 Dielectric Grease Nyogel Additives Miscellaneous 2871326 Carbon Clean 2870652 Fuel Stabilizer 2872189 DOT 4 Brake Fluid 2871956 Loctite 565 Thread Sealant 2859044 POLARIS Battery Tender Charger 136 WARRANTY LIMITED WARRANTY POLARIS Sales 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 arrestor in this product will meet the efficiency requirements of USFS
85. n 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 2014 SPORTSMAN FOREST 800 6X6 Owner s Manual P N 9924416 TABLE OF CONTENTS IntrodUcllOn sscunse e REREERRRERERRRER EE 4 DANGLY iia decd nade e eee ene seek RE 7 Features and Controls 26 Operation ccc ER ERE ETC TRER ES 46 WiReh OGUIde scis ke ek er IRTEFESRRUEERRSAE ES 66 Emission Control Systems 78 Maintenance ss ss 79 Troubleshooting Lssse 130 Specifications L 134 POLARIS Products 136 Warranty s cuecileca Ree tested sede ccees 137 Maintenance Log 141 Index oorirubiece E bxs E RENE anwa 143 INTRODUCTION The following signal words and symbols appear throughout this manual and on your vehicle Your safety is involved when these words and sym bols are used Become familiar with their meanings before reading the manual A The safety alert symbol
86. nd learn to read the terrain Be constantly alert for haz ards such as logs rocks and low hanging branches 3 Travel slowly and use extra caution when operating on unfamiliar terrain Not all obstacles are immediately visible 4 Never attempt to operate over large obstacles such as rocks or fallen trees 60 OPERATION Driving in Reverse Follow these precautions when operating in reverse SOV pA Geop Always check for obstacles or people behind the vehicle Always avoid backing downhill Back slowly Apply the brakes lightly for stopping Avoid turning at sharp angles Never open the throttle suddenly Do not use the override button unless additional wheel speed is required for vehicle movement Use the override with caution as rearward vehicle speed is greatly increased Do not operate at wide open throttle Operate the throttle just enough to maintain a desired speed NOTICE Excessive throttle operation while in the speed limit mode may cause fuel to build in the exhaust resulting in engine popping and or engine damage 61 OPERATION Hauling Cargo A WARNING Overloading the vehicle or carrying or towing cargo improperly can alter vehicle handling and may cause loss of control or brake instability which can result in serious injury or death Always follow these precautions when hauling cargo Never exceed the maximum weight capacity of the vehicle When determining the weight you are adding to th
87. nderstand the load distribution warning labels on the vehicle and never exceed the weight capacities outlined in the specifications section of the owner s manual and on the safety labels The total load operator accessories cargo and weight on hitch must not exceed the maximum weight capacity of the vehicle 2 Always load the cargo box with the load as far forward as possible 3 Always operate the vehicle with extreme caution whenever hauling or towing loads Balance handling and control may be affected 4 Slow down NEVER exceed 50 MPH 80 km h when rear cargo loads are above 75 Ibs 34 kg and or front cargo loads are above 37 lbs 17 kg NEVER exceed 10 MPH 16 km h when rear cargo loads are above 200 lbs 91 kg and or front cargo loads are above 100 Ibs 45 kg 5 The cargo box dump latch must be securely latched before loading and operating Unintentional box tilting will result if weight is placed in the rear of the box and the latch is not secured 6 Always attach a towed load to the hitch point 7 Unbraked Trailer Towing Capacity is 2271 Ibs 1030 kg based on EU Directive 76 432 EC NOTICE Using an improper hitch or exceeding the Maximum maximum tongue weight capacity can 8 25 21 cm result in serious damage to the vehicle and will void your vehicle warranty Never install a hitch longer than 8 25 21 cm Never install automotive accessories on your POLARIS vehicle Always install POLARIS approved or
88. ngine Place the transmission in park Lock the parking brake Always block the rear wheels on the downhill side 65 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 4 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 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 IS DX o Always wear eye protection and heavy gloves when operating the winch 5 Always keep body hair clothing and jewelry clear of the winch cable fairlead and hook when operating winch 6 Never attempt to jerk a load attached to the winch with a moving vehicle See the Shock Loading section on page 75 7 Always keep the area around the vehicle winch winch cable and load clear of people especially children and distractions while operating the winch 8 Always turn the vehicle ignition power OFF when it and the winch are not being used 9 Always be sure that at least five 5 full turns of winch cable are wrapped around the winch drum at all times
89. ns in the RPM from day to day may be normal because of changes in humidity temper ature and elevation 39 FEATURES AND CONTROLS Instrument Cluster Rider Information Center Diagnostic Mode The wrench icon will display when the gauge is in the diagnostic mode To exit the diagnostic mode turn the key switch off and on Any move ment of the tires will also cause the gauge to exit the diagnostic mode To enter the diagnostics mode 1 Turn the key switch off and wait 10 seconds 2 Lock the parking brake 3 Place the transmission in neutral 4 Hold the mode reverse override button and turn the key switch on Release the switch as soon as the display is activated 5 Use the mode button to toggle through the diagnostic screens 40 FEATURES AND CONTROLS Instrument Cluster Rider Information Center Diagnostic Mode Battery Voltage Screen View this screen to check battery voltage level Tachometer Screen View the tachometer to check engine speed 4X4 Diagnostic Screen The gauge indicates whether or not current is flowing through the all wheel drive coil This screen is for informational purposes only Please see your dealer for all major repairs Gear Circuit Diagnostic Screen This screen displays the resistance value in ohms being read at the gear switch input of the gauge This screen is for informational purposes only Please see your dealer for all major repairs Programmable service interval When the hours o
90. nspect pipe D Spark plug 100 H 12M 620 1000 Inspect replace as needed gt Wiring 100 H 12M 620 1000 Inspect for wear routing security apply dielectric grease to connectors subjected to water mud etc D Clutches drive 100 H 12M 620 1000 Inspect clean replace worn and driven parts D Shift selector 200 H 24M 1240 2000 Inspect replace as needed lubricant D Brake fluid 200 H 24M 1240 2000 Change every two years D ADC fluid 200 H 24M 1240 2000 Change every two years gt Fuel filter 200 H 24M 1240 2000 Check for leaks around lines D Replace every 2 years more often under extreme conditions Spark arrester 300 H 36M 1860 3000 Clean out D Toe adjustment Inspect periodically adjust when parts are replaced gt Auxiliary brake Inspect daily adjust as D needed Headlight aim Adjust as needed gt Perform these procedures more often for vehicles subjected to severe use D Have an authorized POLARIS dealer perform these services 82 MAINTENANCE Lubrication Recommendations Check and lubricate all components at the intervals outlined in the Peri odic Maintenance Chart beginning on page 79 Items not listed in the chart should be lubricated at the General Lubrication interval The a arms and lower control arms are lubricated at the factory and no additional lubrication will be needed However if these components are subjected to severe use grease zerks have been provid
91. nstructions of the labels on the vehicle If an informational or graphic label becomes illegible or comes off con tact 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 WARNING Improper vehicle use can result in SEVERE INJURY or DEATH NEVER Operate on public roads A collision can occur with another vehicle Carry passengers Passengers affect balance and steering and increase risk of losing control USE ALCOHOL or DRUGS before or while operating this vehicle Operate at speeds too fast for your skills or the conditions Operate this vehicle on HILLS steeper than 25 degrees To prevent flipover on hilly terrain use throttle and brakes gradually ALWAYS Use an approved HELMET AND PROTECTIVE GEAR Avoid paved surfaces Pavement may seriously affect handling and control Use proper RIDING TECHNIQUES to avoid vehicle overturns on hills and rough terrain and in turns Use OVERRIDE for reverse speed limiter with caution To prevent loss of control never activate override button with open throttle REVERSE operation can be dangerous even at low speeds Steering becomes difficult To prevent flipover avoid sharp turns PARKING BRAKE may relax when used for more than 5 minutes When parking on grades leave shift in forward LOCATE AND READ OWNER S MANUAL FOLLOW ALL INSTRUCTIONS AND WARNINGS
92. nternally 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 44 FEATURES AND CONTROLS Instrument Cluster Rider Information Center Downloading Codes Blink Failure Description Code 12 BEGIN SEQUENCE 22 Throttle Position Sensor Low 22 Throttle Position Sensor High 22 Throttle Position Sensor Out of Adjustment 25 Gear Sensor Signal 31 System Voltage Low 31 System Voltage High 36 Ignition Coil A Prim Sec Circuit Malfunction Open Load Short to Ground 36 Ignition Coil A Prim Sec Circuit Malfunction Shorted Load Short to Battery 37 Ignition Coil B Prim Sec Circuit Malfunction Open Load Short to Ground 37 Ignition Coil B Prim Sec Circuit Malfunction Shorted Load Short to Battery 41 Air Temp Sensor Low Voltage 41 Air Temp Sensor High Voltage 42 Engine Coolant Temp Low Voltage 42 Engine Coolant Temp High Voltage 44 Crank Position Sensor Circuit Fault 45 Barometric Pressure Manifold Air Pressure Sensor Low 46 Barometric Pressure Manifold Air Pressure Sensor High 47 IAC Stepper Motor Open Load 47 IAC Stepper Motor Short to Ground 51 Injector Circuit Malfunction Cyl 1 Open Load Short to Ground 51 Injector Circuit Malfunction Cyl 1 Shorted Load Short to Battery 52 Injector Circuit Malfunction Cyl 2 Open Load Short to
93. ntervals outlined in the Periodic Maintenance Chart beginning on page 79 Maintain the fluid level at the bottom of the fill hole threads The oil capacity is 5 oz 150 ml Do not overfill The fill plug is located on the rear of FILED the gearcase The drain plug is located Drain Plug on the bottom of the gearcase We recommend the use of POLARIS ATV Angle Drive Fluid or GL5 80 90 weight gear lube See page 136 for the part numbers of POLARIS products Oil Check 1 Position the vehicle on a level surface 2 Remove the fill plug Check the oil level 3 Addthe recommended oil as needed to bring the level to the bottom of the fill hole threads Do not overfill 4 Reinstall the fill plug Torque to 14 ft Ibs 19 Nm Oil Change 1 Position the vehicle on a level surface 2 Place a drain pan under the drain hole 3 Remove the drain plug Allow the oil to drain completely 4 Clean and reinstall the drain plug with a new sealing washer Torque to 14 ft lbs 19 Nm 5 Remove the fill plug Add 5 oz 150 ml of the recommended oil Do not overfill 6 Reinstall the fill plug Torque to 14 ft lbs 19 Nm 7 Check for leaks 8 Dispose of used oil properly 90 Middle Gearcase Oil Always check and change the mid dle gearcase oil at the intervals outlined in the Periodic Mainte nance Chart beginning on page 79 We recommend the use of POLARIS ATV Angle Drive Fluid or GL5 80 90 weight gear lube Se
94. nuts and bolts are found see your POLARIS dealer for service before operating the vehicle Side Panel Removal 1 Remove the seat 2 Grasp the rear of the side panel near the rear cab With a firm motion pull the panel outward to disengage the side panel from the grommet Pull the panel downward and rearward to remove it 3 Whenreinstalling side panels align the fasteners and press firmly to secure them amp j Step 1 Step 2 Step 3 Footwell Removal 1 Remove the four screws on Rivets the bottom of the footwell 2 Usea flat screwdriver or sidecutters to remove the plastic rivets securing the footwell to the fenders 3 Remove the footwell Screws 98 MAINTENANCE Tires A WARNING Operating your vehicle with worn tires improperly inflated tires non standard tires or improperly installed tires will affect vehicle handling and could cause an accident resulting in serious injury or death Always follow all tire maintenance procedures as outlined in this manual and on the labels on the vehicle Always use original equipment size and type when replacing tires Refer to the specifications section beginning on page 134 for recom mended tire type size and pressure Tire Tread Depth Always replace tires 1 8 3 mm t when tread depth is worn to 1 8 3 mm or less oD WS Front Wheel Hub Tightening Front wheel bearing tightness and spindle nut retention are critical com ponent operations All service mu
95. olant every 2 years gt ADC fluid ADC Daily Check level daily add as models needed Headlamp taillight Daily Check operation apply dielectric grease if replacing 80 Periodic Maintenance Chart MAINTENANCE Item Maintenance Interval Remarks whichever comes first Hours Calendar Miles Km gt Air filter Weekly Inspect replace as needed main element gt Brake pad wear 10H Monthly 60 100 Inspect periodically D Battery 20H Monthly 125 200 Check terminals clean test gt Engine breather 25H Monthly 155 250 Inspect clean if needed filter if equipped gt Engine oil change 25H 1M 250 400 Break in oil and filter change gt Demand drive fluid 25 H 1M 250 400 Change fluid every 25 hours extreme use if ADC is subjected to extreme use See page 88 gt Demand drive fluid 25 H 1M 250 400 Break in oil level check gt Middle gearcase 25H 1M 250 400 Break in oil level check oil 6x6 gt Rear gearcase oil 25H 1M 250 400 Break in oil level check gt Transmission oil 25H 1M 250 400 Break in oil level check gt General 50 H 3M 310 500 Lubricate all fittings pivots lubrication cables etc Shift linkage 50 H 6M 310 500 Inspect lubricate adjust D Steering 50 H 6M 310 500 Lubricate gt Front suspension 50 H 6M 310 500 Lubricate gt Rear suspension 50 H 6M 310 500 Lubricate D T
96. or 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 79 The following areas need special attention engine oil transmission oil demand drive fluid rear gearcase oil and all grease fittings If the vehicle tips or overturns in water or if the engine stops during or after operating in water restarting can result in serious engine damage Transport the vehicle to your dealer for service before restarting the engine If this is not possible follow the vehicle immersion inspection and drying procedures outlined on page 110 then see your dealer for service at the first opportunity 4 After leaving water test the brakes Apply them lightly several times while driving slowly The friction will help dry out the pads If it s unavoidable to enter water deeper than the footrest level Proceed slowly Avoid rocks and obstacles Balance your weight carefully Avoid sudden movements Maintain a steady rate of speed Do not make sudden turns or stops Do not make sudden throttle changes 59 OPERATION Driving Over Obstacles Pd a id Ee a PA E a Ba 7 aE Bay JO sae Y dee ex r T dir A M SS L e M E s DS Ma we 7n A a Sse G jr i ee UT ae TR bie t Follow these precautions when operating over obstacles 1 Always check for obstacles before operating in a new area 2 Look ahead a
97. or the part numbers of POLARIS products Always follow the manufacturer s mixing recommendations for the freeze protection required in your area Recovery Bottle Coolant The recovery bottle is located on the left side of the vehicle 1 Remove the left side panel See page 98 2 Maintain the coolant level between the minimum and maximum marks on the bottle when the fluid is cool 3 Add coolant as needed Recovery Bottle 94 MAINTENANCE Cooling System Radiator Coolant To ensure that the coolant maintains its ability to protect the engine POLARIS recommends that you drain the system completely every two years and add a fresh mixture of antifreeze and water Replace the coolant any time the cooling system has been drained for maintenance or repair If the recovery bottle has run dry check the level in the radiator Add coolant as needed CAUTION Escaping steam can cause burns Never remove the pressure cap while the engine is warm or hot Always allow the engine to cool before removing the pressure cap 1 Open the front box cover 2 Remove the access panel screws Squeeze the outer i edges of the panel inward to remove the panel Radiator Cap 3 Remove the pressure cap 4 Using a funnel slowly add coolant through the radiator filler neck 5 Reinstall the pressure cap Use of a non standard pres sure cap will not allow the recovery system to function properly Contact your dealer fo
98. ottle cable should stick in an open position when the operator releases the throttle lever the engine will stop and power to the rear wheels will cease 28 FEATURES AND CONTROLS Brake Systems A WARNING Never back down a hill Applying the auxiliary brake when backing down a hill may cause rear tipover which could result in serious injury or death Use caution when applying the rear brake Do not aggressively apply the rear brake when going forward The rear wheels may skid and slide sideways causing loss of control which may result in serious injury or death 4 WARNING Operating the vehicle with a spongy brake lever can result in loss of braking which could cause an accident Never operate the vehicle with a spongy feeling brake lever Always contact your dealer for service before operating the vehicle The braking system is controlled by the two brake levers located on the handlebars The service brake left lever is an all wheel brake Use the service brake for normal braking The auxiliary brake right lever is a middle axle rear brake only 29 FEATURES AND CONTROLS Brake Systems Service Brake Lever Squeeze the service brake lever left lever toward the handlebar to apply the front and rear brakes These brakes are hydraulically acti vated disc brakes Always test brake lever travel and master cylinder fluid level before riding When squeezed the lever should feel firm Any sponginess would indicate
99. ove it Gently rub the affected areas with the steel wool until the corrosion has been removed Clean and polish the wheel as out lined above 123 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 then clean the vehicle as recommended See page 121 Stabilize the Fuel 1 Fill the fuel tank 2 Add POLARIS Carbon Clean Fuel Treatment or POLARIS Fuel Stabilizer Follow the instructions on the container for the recom mended 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 85 Air Filter Air Box 1 Inspect and clean or replace the pre cleaner and air filter 2 Clean the air box 3 Drain the sediment tube 124 MAINTENANCE Cleaning and Storage Storage Tips Fluid Levels Inspect the following fluid levels Change fluids as recommended in the Periodic Maintenance Chart beginning on page 79 Demand drive unit front gearcase ADC fluid ADC models change every two years Rear gearcase Middle gearcase Transmission
100. ove 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 countr
101. r the correct replacement part 6 Reinstall the access panel and secure the front box cover 95 MAINTENANCE Brakes Front Rear Middle Brakes The front rear and middle brakes are hydraulic disc brakes These brakes are self adjusting Under normal operation the diaphragm extends into the reservoir as fluid level drops If the fluid level is low and the diaphragm is not extended a leak is likely and the diaphragm should be replaced To ensure proper diaphragm operation always fill the reservoir as needed whenever the cover is loosened or removed Do not overfill WARNING An over full master cylinder may cause brake drag or brake lock up which could result in serious injury or death Maintain brake fluid at the recommended level Do not overfill The following checks are recommended to keep the brake system in good operating condition Check more often if brakes are used heavily under normal operation 1 Always keep brake fluid at an adequate level See page 31 2 Check the brake system for fluid leaks 3 Check the brakes for excessive travel or spongy feel 4 Check the friction pads for wear damage and looseness Replace brake pads when they are worn to 3 64 1 mm 5 Check the security and surface condition 3 64 1 mm of the disc Clean any grease using a rec ommended brake cleaner or alcohol Do not use spray lubricants or other petroleum based products If you discover any damage cracks excessive cor
102. remove the filter Remove the fabric type pre filter from the main filter Wash the pre filter in soapy water then rinse and let dry Reinstall the pre filter over the main filter Install a new main filter if needed Reinstall the filter into the air box and tighten the clamp Do not over tighten the clamp as filter damage could occur Reinstall the air box cover and the seat 101 MAINTENANCE Fuse Replacement Fuse Feature Supported 5A Speedometer 15A Electronic Fuel Injection 20A Main Fuse Ignition Lighting 20A Accessories 12V Power Receptacle If the engine stops or will not start or if you experience other electrical failures a fuse may need replace ment Locate and correct any short circuits that may have caused the blown fuse then replace the fuse Spare fuses are provided in the rear storage box 1 Open the front box cover 2 Remove the suspect fuse from the fuse panel If the fuse is blown install a new fuse with the same amperage 3 Secure the front box cover 102 MAINTENANCE Lights Poor lighting can result in reduced visibility when driving Headlight and taillight lenses become dirty during normal operation Clean lights frequently and replace burned out lamps promptly Always make sure lights are adjusted properly for best visibility Upper Headlight Lamp Replacement When servicing a halogen lamp don t touch the lamp with bare fingers Oil from
103. replace plug Loose ignition connections Check all connections and tighten Low battery voltage Recharge the battery to 12 8 VDC Incorrect fuel Replace with fresh recommended fuel Clogged air filter Inspect and clean or replace Reverse speed limiter malfunction See your dealer Throttle release switch malfunction See your dealer Other mechanical failure See your dealer Overheated engine Clean radiator screen and core clean engine exterior see your dealer Engine Overheating Possible Cause Debris lodged in screen Solution Remove and clean the screen Pull on the top portion of the screen then remove the lower portion Plugged Radiator Use a garden hose to flush any debris from the radiator fins NOTE High pres sure washers can deform the radiator fins and reduce cooling efficiency 133 SPECIFICATIONS SPORTSMAN FOREST 800 6X6 Maximum Weight Capacity 1115 Ibs 507 kg includes operator cargo accessories Dry Weight 1060 lbs 481 kg 7 based on configuration Fuel Capacity 4 1 gal 15 5 1 Engine Oil Capacity 2 qts 1 9 1 Coolant Capacity 3 6 qts 3 4 1 Demand Drive Fluid Capacity 9 3 oz 275 ml Rear Gearcase Oil Capacity 5 oz 150 ml Mid Gearcase Oil Capacity 17 oz 500 ml Transmission Oil Capacity 15 oz 450 ml Front Rack Storage Box Capacity 100 Ib
104. reservoir will result in trapped air If the level drops below the minimum line add fluid to the maximum line and repeat step 6 before proceeding 7 10 Torque the bleeder valve screws to 80 in Ibs 9 Nm Reinstall the bleeder valve caps Add fresh fluid to the reservoir until the level is between the mini mum and maximum marks Make sure the reservoir is free of debris Reinstall the cap securely Clean up any drips or spills 93 MAINTENANCE Cooling System The engine coolant level is controlled or maintained by the recovery system The recovery system components are the recovery bottle the radiator filler neck the radiator pressure cap and the connecting hose As coolant operating temperature increases the expanding heated excess coolant is forced out of the engine past the pressure cap and into the recovery bottle As engine coolant temperature decreases the con tracting cooled coolant is drawn back up from the bottle past the pres sure cap and into the radiator Some coolant level drop on new vehicles is normal as the system is purging itself of trapped air Check the coolant level and maintain as recommended by adding coolant to the recovery bottle POLARIS recommends the use of POLARIS Antifreeze 60 40 premix or a 50 50 mixture of high quality aluminum compatible anti freeze coolant and distilled water POLARIS Antifreeze is already premixed and ready to use Do not dilute with water See page 136 f
105. rn If all forward speed is lost e e lf t 16 Always maintain a steady speed when climbing a hill Always move the 4X4 switch to ADC 4X4 if equipped before ascending or descending a hill See page 36 Keep body weight uphill Apply the service brakes Lock the parking brake when fully stopped a ae on uphill side or to either side if the vehicle is pointed straight uphill Turn the vehicle around and remount following the procedure described in the owner s manual See page 58 he vehicle begins rolling downhill Keep body weight uphill Never apply engine power Never apply the rear brake while rolling backwards Apply the service brake gradually MA A fully stopped apply the rear brake as well and then lock the parking rake ELEME on uphill side or to either side if the vehicle is pointed straight uphill Turn the vehicle around and remount following the procedure described in the owner s manual See page 58 SAFETY Safety Warnings Operating on Steep Hills Operating on excessively steep hills could cause an overturn Never operate on hills too steep for the vehicle or for your abilities Never operate the vehicle on hills steeper than 25 degrees Operating on Slippery Terrain Failure to use extra caution when operating on excessively rough slippery or loose terrain could cause loss of traction loss of control accident or overturn Do not operate on excessively rou
106. rosion warping see your dealer for service before operating 96 MAINTENANCE Toe Alignment Use the following procedure to check the toe alignment of the vehicle The recommended toe alignment is 1 8 to 1 4 3 6 mm toe out WARNING Severe injury or death can result from improper toe alignment and adjustment Do not attempt to adjust tie rod alignment All tie rod adjustments should be performed by an authorized POLARIS dealer Position the vehicle on a level surface 2 Place the handlebars in a Gu straight ahead position oe OSS 3 Tiea length of string between X2 two stands as shown in the ISTA A illustration Position the stands so that the string is RET flush with the side of the rear Sp tire If available you may use String 5321 a long straight edge instead SAY of string 4 Measure the distance from the string to the rim at the front 1 and rear 2 of the front rim The rear measurement should be 1 16 1 8 2 3 mm more than the front measurement on each side of the vehicle to obtain the recommended 1 8 to 1 4 3 6 mm toe out alignment 5 Repeat the measurement procedure on the other side of the vehicle 6 If you discover improper alignment see your POLARIS dealer for service 97 MAINTENANCE Steering Assembly The steering assembly of the vehicle should be checked periodically for loose nuts and bolts If loose
107. rtainty 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 78 MAINTENANCE Periodic Maintenance Chart 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 use genuine POLARIS parts available from your POLARIS dealer Record maintenance and service in the Maintenance Log beginning on page 141 Service and adjustments are important for proper vehicle operation If you re not familiar with safe service and adjustment procedures have a qualified dealer perform these operations Maintenance intervals in the following chart are based upon average rid ing conditions and an average vehicle speed of approximately 10 miles per hour Vehicles subjected to severe use must be inspected and ser viced more frequently Severe Use Definition Frequent immersion in mud water or sand 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 leve
108. s 45 kg Cargo Box Capacity 800 Ibs 363 kg Unbraked Trailer Towing Capacity 2271 Ibs 1030 kg Overall Length 112 in 284 cm Overall Width 48 in 122 cm Overall Height 48 in 122 cm Wheelbase 79 5 in 202 cm Ground Clearance 10 5 in 27 cm Minimum Turning Radius 152 in 386 cm unloaded Engine SPM800 4 Stroke Low Torque Capacity Displacement 760 cc Engine Power 41 kW Bore x Stroke 80 x 76 Alternator Output 500 Watts 3000 rpm Compression Ratio 10 1 Starting System Electric Fuel System Electronic Fuel Injection Ignition System ECU Ignition Timing 8 BTDC 2000 RPM Spark Plug Gap RC7YC 035 in 0 9 mm Lubrication System Pressurized Wet Sump Seat Single Seat length 650 mm Steering System Akerman Principle with handlebar controls Transmission Power System Shaft drive on all wheels Driving System Type Automatic PVT POLARIS Variable Transmission Front Suspension MacPherson strut with 8 2 21 cm travel Rear Suspension Progressive rate with 6 1 15 5 cm travel Based on EU Directive 76 432 EC 134 SPECIFICATIONS SPORTSMAN FOREST 800 6X6 Transmission Automatic PVT with E Z Shift H L N R P Gear Reduction Low 7 49 1 Gear Reduction Reverse 5 11 1 Gear Reduction High 3 05 1 Drive Ratio Front 3 82 1 Drive Ratio Final 3 10 1
109. st be performed by your authorized POLARIS dealer Wheel Removal 1 Stop the engine 2 Place the transmission in park 3 Lock the parking brake 4 Loosen the wheel nuts slightly WARNING Do not service axle nuts that have a cotter pin installed See your POLARIS dealer 5 Elevate the side of the vehicle by placing a suitable stand under the footrest frame 6 Remove the wheel nuts 7 Remove the wheel 99 MAINTENANCE Tires Wheel Installation Place the transmission in park 2 Lockthe parking brake 3 Place the wheel on the hub with the valve stem toward the outside and rotation arrows on the tire pointing toward forward rotation 4 Install the wheel nuts and finger tighten them 5 Lower the vehicle to the ground 6 Torque the wheel nuts to specification WARNING Loose nuts could cause a tire to come off during operation which could result in an accident or overturn Always ensure that all nuts are torqued to specification Wheel Nut Torque Specifications Check the wheel nut torques occasionally and when they ve been loos ened for maintenance service Nut Type Nut Torque Lug Nut Aluminum C 30 ft lbs 41 Nm Wheels ss gD PLUS 1 4 TURN B LZ 2 Piece Flange Nut DA 27 ft Ibs 37 Nm Steel Wheels tO 100 MAINTENANCE Air Filter 1 2 Remove the seat Pre Filter Release the air box cover clips and remove the air box cover Main Filter Loosen the clamp and
110. to operate this vehicle unless the guest has read this manual and all product labels and has completed a certified safety training course 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 VIN ee Sa front or rear frame Key Number Vehicle Model Number Frame VIN Engine Serial Number Key Number SAFETY Safety Training Never operate this vehicle without proper instruction Take a training course For more information about safety contact an authorized POLARIS dealer or visit the POLARIS web site at www polaris com SAFETY Safe Riding Gear Always wear appropriate clothing when riding this vehicle Wear pro tective clothing for comfort and to reduce the chance of injury Eye Protection Helmet Long Gloves Sleeves Long Pants Helmet Wearing a helmet can prevent a severe head injury Whenever riding a POLARIS vehicle always wear a helmet that meets or exceeds estab lished safety standards Approved helmets in the USA and Canada bear a U S Department of Transportation DOT label Approved helmets in Europe Asia and Oceania
111. urfaces Keep both feet on the footrests Shift body weight uphill Proceed at a steady rate of speed and throttle opening Opening the throttle suddenly could cause the vehicle to flip over backwards 9o mE gv Ur de px P3 9 Remain alert and be prepared to take emergency action This may include quick dismounting of the vehicle 55 OPERATION Driving on a Sidehill Sidehilling Driving on a sidehill is not recommended Improper procedure could cause loss of control or overturn Avoid crossing the side of any hill unless absolutely necessary If crossing a sidehill is unavoidable follow these precautions Slow down Avoid crossing the side of a steep hill Shift body weight uphill Keep your feet on the footrests If the vehicle begins to tip quickly turn the front wheel downhill if possible or dismount on the uphill side immediately ON ee bo 56 OPERATION Driving Downhill 25 Maximum When driving downhill follow these precautions 1 AE 2B Always move the 4X4 switch to ADC 4X4 if equipped before ascending or descending a hill See page 36 Avoid steep hills 25 maximum Shift body weight uphill Drive straight downhill Slow down Excessive speed when traveling downhill can cause loss of control Squeeze the brake lever gradually Applying the brakes too firmly may cause the rear wheels to lock which could result in loss of con trol 57 OPERATION Turning Around on a Hill
112. use 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 76 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 winchin
113. y from the headlight assembly Remove the headlamp and install the new headlamp Reinstall the harness assembly into the headlight assembly Turn the headlight harness clock wise to secure the headlamp Taillight Brakelight Lamp Replacement 1 Ui de po S Remove the taillight lens cover mounting screws Remove the lens cover and gasket and set aside for reassembly Remove the lamp Apply dielectric grease to the socket and install the new lamp Test the light for proper operation Reinstall the gasket and lens cover 107 MAINTENANCE Spark Plugs Spark Plug Recommendations Refer to the specifications section beginning on page 134 for the recom mended spark plug type and gap for your vehicle Torque spark plugs to specification NOTICE Using non recommended spark plugs can result in serious engine damage Always use POLARIS recommended spark plugs Plug Condition Torque Specification New Spark Plug 9 11 ft Ibs 12 15 Nm Previously Installed Spark Plug 17 20 ft Ibs 23 27 Nm Spark Plug Inspection Spark plug condition is indicative of engine operation Check the spark plug firing end condition after the engine has been warmed up and the vehicle has been driven at higher speeds Immediately check the spark plugs for correct color See page 109 CAUTION A hot exhaust system and engine can cause burns Wear protective gloves when removing a spark plug for inspection 1 Rotate t
114. y Switchs seei eeir 27 K T thi ure Er Es s 58 144 L Light Switch ecce oes tae 26 Lights 0c cece eee 103 107 Headlight Housing 106 Headlight Lamp Upper 103 High Beam Adjustment 104 Low Beam Adjustment 105 Lower Headlamp 107 Taillight Brakelight 107 Low Beam Adjustment 105 Low Range Use 114 Lower Headlamp Replacement 107 Lubrication Recommendations 83 M Maintenance Chart 79 82 Master Cylinder sues 31 Middle Gearcase Oil Check 91 Middle Gearcase Oil Change 91 Mode Switch ees sre re tases 26 Modifications 0005 9 N Noise Emission Control System 78 Oo Oil 13 019410 2d ee Ree 84 86 Middle Gearcase 91 Rear Gearcase sues 90 Transmission sees 87 Oil and Filter Change 85 86 Oil Change Middle Gearcase 91 Oil Check Middle Gearcase 91 Oil Level Engine 84 Oil Recommendations 84 Override Switch 0 26 P Parking Br ke els 32 Parking on an Incline 65 Periodic Maintenance Chart 79 82 Polaris Product List 136 Polishing the Vehicle 122 Pre Ride Checklist 48 PVT Break In ever 47 PVT Drying ee tmr sss 114 PVT System ioc acd eine anaes 112 114 R Reverse Operation 61 Reverse Ov
115. y hand or with a garden hose using mild soap Certain products including insect repellents and chemicals will damage the speedometer lens and other plastic surfaces Do not use alcohol to clean the instrument cluster Do not allow insect sprays to contact the lens Immediately clean off any gasoline that splashes on the instrument cluster 37 FEATURES AND CONTROLS Instrument Cluster Rider Information Center The rider information center is located in the instrument cluster All seg ments will light up for 2 5 seconds 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 speedome ter If this occurs take the vehicle to your POLARIS dealer for proper diagnosis 1 38 Gear Indicator This 3 4 5 6 7 indicator displays gear shifter position H High Gear L Low Gear N Neutral R Reverse Gear P Park 2 4X4 Indicator This indicator illuminates SSS pee when the 4X4 switch is 1 on either ADC 4X4 or 4X4 Engine Hour Display Indicator Service Interval Diagnostic Mode Indicator Low Battery and 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 elec trical load lights cooling fan accessories is applied Drive at a higher RPM or recharge the battery to clear the warning
116. y 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 139 WARRANTY 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 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 d
117. your skin leaves a residue causing a hot spot that will shorten the life of the lamp 1 Remove the two screws on the lower front corners of the headlight pod 2 Remove the screw from the rear of the pod 3 Liftthe pod slightly while depressing the tabs at the rear of the pod 4 Liftthe pod cover and disconnect the speedometer harnesses from the speedometer CAUTION Hot components can cause burns to skin Allow lamps to cool before servicing 5 Unplug the headlamp from the wiring harness Be sure to pull on the connector not on the wiring 6 Turn the lamp counter clockwise to remove it 7 Apply dielectric grease to the socket and install the new lamp Make sure the tab on the lamp locates properly in the housing 8 Reassemble the pod 103 MAINTENANCE Lights High Beam Adjustment The headlight beam can be adjusted slightly upward or downward Use the following procedure to make the adjustment 1 Position the vehicle on a level surface with the headlight approxi mately 25 ft 7 6 m from a wall Place the transmission in park 2 5 cm 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 Start the engine Turn the headlight switch to high beam 4 Observe the headlight aim on the wall The most intense part of the headlight beam should be two inches 5 cm below the mark on the wall Include rider weight on the seat when measuring

Polaris 9922483 Offroad Vehicle User Manual

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