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Polaris 9921837 Offroad Vehicle User Manual

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1. 00 00s eee eee 61 SPECHICALIONS iare ce wees eae Sas 116 Polaris ProdguClSis ct cacneveeeecdtuada es 118 Troubleshooting 0 0000eeeeeee 119 Warran y o 6 355 b ott hind deed A 123 Maintenance Log 0000 ee enue 126 NAEK iii cece Sei eae a ee eee 128 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 indicates a potential personal injury hazard WARNING A WARNING indicates a hazardous situation which if not avoided may result in death or serious injury CAUTION A CAUTION indicates a hazardous situation which if not avoided may result in minor or moderate injury NOTICE A NOTICE indicates a situation that may 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 follow the warnings in this manual can result in serious injury or death A Polaris Tractor is not a toy and can be hazardous to operate A collision or rollover can occur quickly even during routine maneuvers if you fail to take proper precautions e Read this owner s manual Understand all safety warnings precautions and operating procedures before operat
2. 24 Brakes earan ra E aut 24 83 Break In Period 40 Breather Pitter 2200305253 ad dedas 91 Breather HOS 32 oxo eins Sd Bhd 91 C CAL Oy eraen oe Bae OL ORAS 58 59 Cargo Loading 37 Chrome Wheel Care 111 Cleaning and Storage 109 114 Clock Setting Time 34 CIOMMNG serre Groeten eds 86 Be 9 Chute inps 0 ocsoe ay rar GR Ped oo 117 128 C Cold Weather Operation 43 Coolant Bottle rre snene es 78 Coolant Radiator 79 Cooling System 78 79 Corrosion Removal Chrome 111 D Demand Drive Fluid 74 75 Disengaging Active Descent Control 30 Drive Belt Wear Burn 119 Drivetrain Break In 40 Driving Downhill 49 Driving in Reverse 56 Driving on a Sidehill 48 Driving on Slippery Surfaces 54 Driving Over Obstacles 55 Driving Procedures 44 Driving Through Water 52 53 Driving Uphill 46 47 Driving with a Passenger 45 E Electromagnetic Interference 60 Electronic Throttle Control 23 Engaging 4X4 oc ete eee as 29 Engaging Active Descent Control 30 Engine Break In 40 Engine Fogging 113 Piene Os 25 ois ann 8d wate 2 8 66 71 Equipment Modifications I Exhaust Emission Control System 60 Eye Protecti one car ose ete Moe apes 9 F Fluid
3. 60 MAINTENANCE Periodic Maintenance Chart Maintenance intervals in the following chart are based upon average riding conditions Vehicles subjected to severe use must be inspected and serviced more frequently The programmable service interval mode on the instrument cluster will help determine when maintenance service is due See page 31 Record maintenance and service in the Maintenance Log beginning on page 126 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 Severe Use Definition e Frequent immersion in mud water or sand e Racing or race style high RPM use e Prolonged low speed heavy load operation e Extended idle e Short trip cold weather operation Pay special attention to the oil level A rise in oil level during cold weather can indicate contaminants collecting in the oil sump or crank case Change oil immediately if the oil level begins to rise Monitor the oil level and if it continues to rise discontinue use and determine the cause or see your dealer 6l MAINTENANCE Periodic Maintenance Chart A Improperly performing the procedures marked with a could result in component failure and lead to serious injury or death Have an authorized Polaris dealer perform these services Maintenance Chart Key gt Perform these operations more often for vehicles subjected to
4. 38 FEATURES AND CONTROLS Instrument Cluster Rider Information Center Downloading Codes Blink Failure Description Code System Voltage High System Voltage High S O 36 Ignition Coil A Prim Sec Circuit Malfunction Open Load Short to Ground 59 63 63 73 39 OPERATION Break In Period The break in period for your new Polaris Tractor is the first ten hours of operation or the time it takes to use the first two full tanks of gasoline No single action on your part will increase the life and performance of your Tractor more than following the procedures 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 Do not operate at full throttle or high speeds for extended periods during the first three hours of use Engine and Drivetrain Break in 1 Fill the fuel tank with the recommended fuel See page 27 2 Check the engine oil level See page 66 Add oil if necessary 3 Select an open area that allows room to familiarize yourself with vehicle operation and handling 4 Drive slowly 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 41 6 Pull only light loads 7 Change both the oil and the filter at 20 hours or one month which ever comes first PVT Break in Clutc
5. IS a 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 7 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 8 Mode Indicator 32 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 20 The transmission cannot be in reverse when using this feature Odometer Mode The odometer records the miles or kilometers traveled by the Tractor Trip Meter Mode The trip meter records the miles or kilometers traveled by the Tractor 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 fluctuations
6. This warranty gives you specific legal rights and you may also have other rights which vary from state to state If any of the above terms are void because of state or federal law all other warranty terms will remain in effect 125 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 KILOMETERS TECHNICIAN SERVICE PERFORMED COMMENTS OR HOURS 126 KILOMETERS OR HOURS MAINTENANCE LOG TECHNICIAN SERVICE PERFORMED COMMENTS 127 INDEX 0 9 AXA Syste Meurer Aee ea 28 29 A CCESSOTIES nannan nananana 114 Active Descent Control Fluid 76 77 Active Descent Control System 30 ADC System 30 AIP PGC i op ot ees cs coe ee 90 All Wheel Drive Switch 22 All Wheel Drive System 28 29 B Backrest Adjustment 25 Battery sesso Gatase bees 104 108 Charging Conventional 107 Charging Sealed 107 108 Fluid Conventional 106 Installation 105 REMOVAL sched th Ee Sie ate 105 SOLIDO ree EENET EDESA 106 BOOS 2 i uek ten t tnea a oa 9 Brake Fluid 80 82 Brake Inspections 83 Brake LACM ark Gast 4 adult wets 94 Brake Maintenance 83 Brake Foot 24 82 Brake Hand 24 81 Brake Parking
7. Active Descent Control 76 77 Brake aeei sannu iaka aa 80 82 Demand Drive 74 75 Poeme Olle ostaman etais 66 71 Front Gearcase 74 75 Transmission 72 73 F Fluid Change ADC Plaids Soc does pee he Sass Ti Demand Drive 75 Engine Oil 68 71 Front Gearcase 75 Transmission 73 Fluid Level ADC Fluidics osua sts uss 76 Brake Fluid 81 82 Demand Drive 74 Engine Oil 67 Front Gearcase 74 Transmission 72 Fluid Recommendations ADC Fud orari dan EEA 76 Brake Fluid 80 Demand Drive 74 Fnoine Qil oscriceisesi nas 66 Front Gearcase 74 Transmission T2 Foot Brake 24 82 Footwell Removal 86 Front Gearcase Fluid 74 75 FUSI PING x ot alate ete teed 90 Puech Tapk Cap nc 22 22 82 s sobis tetas 21 Buel Valves renias fe ede Sas ik 2 Fuse Replacement 95 G Gear Selector y 2 4 4 panua ia ob 27 E E hea tetas cok EA ane 9 H Hand Brake 8 Handlebar Adjustment 85 Hauling Cargo 57 59 Hazard Warning Switch 22 Headlight Lamp 93 HEE edL ek ea eee 8 High Beam Adjustment 92 High Range Uses cceachs bag Yas oes 43 H INC NCS OGD sare cieu be See nS 26 HOM SWitCh pesue dare eee eax e aces 22 Hub Tig
8. Drain the sediment tube 112 MAINTENANCE Cleaning and Storage Storage Tips Fluid Levels Inspect the fluid levels Add or change fluids as recommended in the Periodic Maintenance Chart beginning on page 61 e Demand drive unit front gearcase e ADC fluid change every two years e Rear gearcase if equipped e Transmission e Brake fluid change every two years and any time the fluid looks dark or contaminated e Coolant test strength fill Fog the Engine 1 Treat the fuel system with Polaris Carbon Clean See page 112 2 Remove the spark plug Pour 30 45 ml of engine oil into the plug holes 3 Reinstall the spark plug Torque to specification 4 Apply dielectric grease to the inside of each spark plug cap Rein stall the caps 5 Turn the engine over several times using electric start Oil will be forced in and around the piston rings and ring lands coating the cyl inder with a protective film of fresh oil 6 If Polaris fuel system additive is not used the fuel tank fuel lines and injectors should be completely drained of gasoline 113 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 61 Battery Storage See pages 106 107 for storage and charging procedures Storage Area Covers 1 Set the tire pressure and safely support the vehicle with the tires sl
9. Lower the vehicle to the ground Torque the wheel nuts to specification See torque chart on page 88 89 MAINTENANCE Fuel Filter The in line fuel filter should be replaced by your dealer after every 100 hours of operation or annually Do not attempt to clean the fuel filter Air Filter Always clean and replace the air and breather filters at the intervals out lined in the Periodic Maintenance Chart beginning on page 61 1 Position the vehicle on a level surface 2 Place the transmission in PARK 3 Remove the seat Release the air box cover clips 5 Remove the air box cover 6 Loosen the hose Pre Filter clamp E 7 Remove the filter 70 Main Filter 8 Remove the pre filter L from the filter f 9 Wash the pre filter in soapy water Rinse and air dry Replace the fil ter if needed 10 Reverse the steps to reinstall all components 90 MAINTENANCE Breather Filter Hose The breather filter is on the hose between the engine and air box 1 Remove the left side panel See page 86 2 Remove the hose clamps from the filter and pull the filter out of the hoses 3 Inspect the filter for debris Blow gently through the filter in the SI f w direction of the arrow to check Male i for clogging Replace a damaged Breather Filter or clogged filter 4 Check the hoses for cracks deterioration abrasion or leaks Replace as needed 5 Reinstall the filter and hose clam
10. 1 Place the transmission in PARK Open the front rack cover 3 Remove the plug at the back of the na tt headlight l 4 Pull the harness plug to disconnect it from the back of the headlight 5 Position light Rotate the socket to remove it Go to step 6 Headlamp Reach under the bumper and remove the rubber cover from the back of the headlight Turn the collar counter clockwise and carefully remove the collar and socket gt as Headlamp 6 Remove the lamp Apply dielectric grease to the socket and install a new lamp 7 Reverse all steps to reassemble the headlight 93 MAINTENANCE Lights Taillight Brake Light Lamp Replacement 1 Place the transmission in PARK 2 Rotate the taillight socket counter clockwise to remove it 3 Remove the lamp Apply dielectric grease to the socket 5 Install the new lamp Test the lamp for proper operation 6 Reinstall all components in reverse order Front Turn Signal Lamp Replacement 1 Place the transmission in PARK J 2 Remove the lens attachment screws 3 Rotate the lamp to remove it Install the new lamp 5 Reinstall the lens Screws Rear Turn Signal Lamp Replacement 1 Place the transmission in PARK 2 Rotate the turn signal socket counter clockwise to remove it 3 Remove the lamp Apply dielectric grease to the socket 5 Install the new lamp Test the lamp for proper operation 6 Reinstall all components
11. 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 con sumption use of non recommended oil or incorrect throttle body adjust ments 96 Spark Plugs Spark Plug Removal Remove the left side panel See page 86 Remove the spark plug cap Use the spark plug wrench to remove the spark plug Turn the plug counterclockwise to remove it Inspect the electrodes for wear and carbon buildup Replace worn or fouled plugs Verify that the gap is at specification before installation Reinstall the spark plug Torque to specification See page 96 Reinstall the spark plug cap MAINTENANCE 97 MAINTENANCE Vehicle Immersion If your vehicle has been totally submerged in water and it s impossible to have it serviced before further operation perform the following pro cedure NOTICE Ifthe vehicle stops while fully submerged major engine damage can result if the machine is not thoroughly inspected Take the vehicle to your dealer before starting the engine 1 Move the vehicle out of the water 2 Remove the spark plug it 3 Drain any water found in the air box 98 Vehicle Immersion 4 Turn the ignition key past the PARKING LIGHTS position to engage the starter Engage the starter for only 2 3 seconds Dry the spark plug Reinstall
12. 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 remove 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 111 MAINTENANCE Cleaning and Storage Storage Tips NOTICE Starting the engine during the storage period will disturb the protective film created by fogging and damage could occur Never start the engine during the storage period Clean the Exterior Make any necessary repairs and clean the vehicle as recommended See page 109 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 recommended amount Carbon Clean removes water from fuel systems stabilizes fuel and removes carbon deposits from pistons rings valves and exhaust systems 3 Allow the engine to run for 15 20 minutes to allow the stabilizer to disperse through the entire fuel delivery system Oil and Filter Change the oil and filter See page 68 Air Filter Air Box 1 Inspect and clean or replace the pre cleaner and air filter See page 90 Clean the air box Clean or replace the breather filter See page 91 AWN
13. Se 4X4 Switch Horn Switch Turn Signal Switch MAIER Master Light Switch The master light switch must be in the ON position to allow operation of the headlights parking lights and taillights Mode Reverse Override Switch Press the switch to toggle through the speedometer display modes except in reverse See page 31 To gain additional power while operating in reverse press the override switch before opening the throttle This will cancel the reverse speed limit function The override switch also allows activation of 4X4 in reverse 1f the 4X4 switch is on A Activating the override switch while the throttle is open can cause loss of control Do not activate the override switch while the throttle is open 20 FEATURES AND CONTROLS Switches Main Key Switch X foe End all electrical power to the vehicle a AD The LIGHTS ON position turns the headlights on The master light switch must be on and the engine stop switch must be in the RUN position Start the engine The headlights are not on in this position p 0E After starting the engine release the key switch to the PARKING LIGHTS ON position The headlights and taillights are on in this position A Do not attach a large key fob or key ring to the main switch It may contact the gas tank cap when turning causing an interruption to the electrical system and an unexpected engine shut down during operation This could result in serious injury or d
14. 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 104 MAINTENANCE Battery A Improperly connecting or disconnecting battery cables can result in an explosion and cause serious injury or death When removing the battery always disconnect the negative black cable first When reinstalling the battery always connect the negative black cable last Battery Removal 1 Place the transmission in PARK Disconnect the battery hold down strap Remove the battery cover if equipped On conventional batteries remove the battery vent tube 3 Disconnect the black negative battery cable first Disconnect the red positive battery cable last 4 Lift the battery out of the vehicle Be careful not to tip a conven tional battery sideways which could spill electrolyte If electrolyte spills immediately wash it off with a solution of one tablespoon baking soda and one cup water to prevent damage to the vehicle Battery Installation 1 Ensure that the battery is fully char
15. fluid to the reservoir until the level is between the minimum and maximum marks Make sure the reservoir is free of debris Reinstall the cap securely Clean up any drips or spills 71 MAINTENANCE Cooling System Any time the cooling system has been drained for maintenance or repair replace the coolant with a fresh mixture of antifreeze and water Drain the cooling system every two years Add fresh coolant Polaris recommends the use of Polaris Premium 60 40 anti freeze cool ant or a 50 50 mixture of high quality aluminum compatible anti freeze coolant and distilled water Polaris Premium 60 40 is premixed and ready to use Do not dilute with water See page 118 for the part num bers of Polaris products Always follow the manufacturer s mixing recommendations for the freeze protection required in your area Recovery Bottle Coolant Some coolant level drop on new machines is Z wea normal as the system is purging itself of trapped hee 7 a air Add coolant as needed E jagu Check the coolant level in the radiator any time a A V the recovery bottle has run dry Add coolant as NS oo needed 1 Check the coolant level when the fluid is cool 2 Remove the left side panel See page 86 3 View the coolant level Maintain the coolant level between the minimum and maximum marks on the bottle when the fluid is cool 4 Add coolant as needed 5 Reinstall the side panel 78 MAINTENANCE Cooling System Ra
16. instructions for minor maintenance but informa tion 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 For more information about Polaris visit us online at www polarisindustries com Ch POLARIS The Way Out POLARIS and POLARIS THE WAY OUT are registered trademarks of Polaris Indus tries Inc Copyright 2008 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 production components some minor discrep ancies may result between the actual vehicle and the information presented in this publi cation Depictions and or procedures in this publication are intended for reference use only No liability can be accepted for omissions or inaccuracies Any reprinting or reuse of the depictions and or procedures contained within whether whole or in part is expressly prohibited Printed in U S A 2009 Sportsman 500 EFI Tractor Owner s Manual P N 9921837 2 TABLE OF CONTENTS ITUTFOGUICHIONN si sice te neve E Sel iw eal ee 4 SAG ohh bh eas ed oe See ee ee 7 Features and Controls 00005 20 ODG aliOn ss6esdeeeek tin enen ans 40 Emission Control Systems 60 Maintenance
17. water is accidently ingested into the PVT system Dry it out before operating l 2 Position the vehicle on a level surface Place the transmission in PARK Remove the drain plug Allow the water to drain completely Rein stall the drain plug Start the engine 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 Allow the engine RPM to settle to idle speed then shift the trans mission to the lowest available range Test for belt slippage If the belt slips repeat the process Take the vehicle to your dealer for service as soon as possible 103 MAINTENANCE Battery A 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
18. 0 Inspect level Inspect level change yearly yearly LAEE breather L ah clean Ha eto Da needed filter if equipped Engine oil change Perform a break in oil change break in at one month General Lubricate all fittings pivots lubrication cables etc Shift linkage 50 6M 800 nspect lubricate adjust Seeng so em 60 Lubricate Biot a Ee gt Rear suspension Rear suspension 800 Lubricate AR cable m E C lubricate ETC switch replace if necessary eee inet au Inspect duct for proper seal Finca duct ing air leaks jee belt ae adjust replace as ae ee ed Ls system 1600 Inspect coolant strength seasonally pressure test system yearly E oil change a Perform a break in oil change Ae ae one month il neal filter Oil filter change 100 1600 Replace with oil Replace with oil change e tank vent hose ECA a oe routing condition if equipped 63 MAINTENANCE Periodic Maintenance Chart Maintenance Interval whichever comes first roo ew 10 Liles system 12 feted 1600 Check for leaks at tank cap lines filter pump replace lines every 2 years eee Inspect clean external ee ee i incall Cooling hoses 1600 Inspect for leaks gt Engine mounts mounts 100 12 12M _ 1600 Inspect dei E EE 12 a a Inspect pipe aoe plug 12 e e Inspect replace as needed e 12 Bad Bl Inspect for wear routing security apply dielectric grease to connector
19. CIAL DAMAGES OF ANY DESCRIP TION WHETHER ARISING OUT OF EXPRESS OR IMPLIED WARRANTY OR ANY OTHER CONTRACT NEGLIGENCE OR OTHER TORT OR OTHERWISE Some states do not permit the exclusion or limitation of incidental or consequential damages or implied warranties so the above limitations or exclusions may not apply to you if inconsistent with controlling state law ALL IMPLIED WARRANTIES INCLUDING BUT NOT LIMITED TO THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PAR TICULAR PURPOSE ARE LIMITED IN DURATION TO THE ABOVE TWO YEAR WARRANTY PERIOD POLARIS FURTHER DISCLAIMS ALL EXPRESS WARRANTIES NOT STATED IN THIS WARRANTY Some states do not allow limi tations on how long an implied warranty lasts so the above limitation may not apply to you if inconsistent with controlling state law 124 WARRANTY HOW TO OBTAIN WARRANTY SERVICE If your vehicle requires warranty service you must take it to a Polaris dealer authorized to repair Polaris Tractors When requesting warranty service you must present your copy of the Warranty Registration form to the dealer THE COST OF TRANSPORTATION TO AND FROM THE DEALER IS YOUR RESPONSIBILITY Polaris suggests that you use your original selling dealer however you may use any Polaris Servicing Dealer to perform warranty service Please work with your dealer to resolve any warranty issues Should your dealer require any additional assistance they will contact the appropriate personnel at Polaris
20. Do not start or operate a Tractor with sticking or improperly operating throttle controls Contact your dealer for repair if throttle problems arise Press the throttle lever to increase engine speed and vehicle movement Release the lever to reduce engine speed and vehicle movement Electronic Throttle Control ETC ETC causes the engine to Electronic Throttle Control stop if the throttle cable sticks in an open position when the operator releases the throttle lever The Electronic Throttle Control ETC stops the engine in the event of a throttle system malfunction Do not modify this safety feature or replace it with other throttle mechanisms 23 FEATURES AND CONTROLS Brakes A Aggressively applying the brakes when backing down a hill may cause rear tipover Aggressively applying the brakes while moving forward may cause the rear wheels to skid and result in loss of control Read this owner s manual and understand the operation of all brake systems on this vehicle Always use caution whenever applying the brakes Foot Brake The all wheel foot brake 1s located on the right footrest The foot brake operates both front and rear brakes Press the brake pedal down with your foot to apply the all wheel brakes If the rear wheels begin to skid or slide while using the foot brake reduce brake pressure Hand Brake Lever The hand brake operates both front and rear brakes Squeeze the brake lever toward the hand
21. EW 2 LE 4 Tire Pressure ge S87 G Load Alert 2 D A Tire Pressure Load Alert TIRE PRESSURE IN PSI kPa FRONT 5 34 5 REAR 5 34 5 MAXIMUM WEIGHT CAPACITY 420 LBS 191 kg INCLUDES WEIGHT OF OPERATOR CARGO AND ACCESSORIES Read Owner s Manual for more detailed loading information 7174877 A Reverse Override Alert 4X4 AWD Switch WARNING Pushing reverse override button may cause sudden increases in power and traction if too much throttle is applied Loss of control or forward flipover may result especially in 4X4 AWD See Owner s Manual 4X4 AWD SWITCH Do not push switch to engage 4X4 AWD if the rear wheels are spinning This may cause severe drive shaft and clutch damage See your Owner s Manual 7175106 18 SAFETY Safety Labels and Locations A No Passenger Warning WARNING NEVER ride as a passenger Passengers can cause a loss of control resulting in SEVERE INJURY or DEATH 7175378 A Clutch Cover Alert NO STEP 7173030 A Rack Warning WARNING e 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 e Max Rack Loads Front 90 Ibs 41 kg Rear 180 Ibs 82 kg 7172572 19 FEATURES AND CONTROLS Switches Mode Reverse Override Switch Engine Stop Switch Master Light Hazard Sy Switch G RS lt lt Ca al a CSS shi Lo A Oy IER if K Headlight l
22. Pantone 426c _ E POLARIS The Way Out sportsman 300 EFI Tractor 2009 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 E E Pantone 426c CD CE CF QD CD CP Cs Before you operate this vehicle read the owner s manual Lesen Sie die Bedienungsanleitung bevor Sie dieses Fahrzeug fahren Antes de conducir este vehiculo lea el Manual del propietario Lire le Manuel du propri taire avant d utiliser ce vehicule Prima di usare il veicolo leggete il Manuale di istruzioni Lue aina kayttoohjekirja ennen taman ajoneuvon kayttoa Antes de utilizar este ve culo leia o Manual do proprietario Innan du kor detta fordon las Handboken PELARIS For your nearest Polaris dealer The Way Out visit www polarisindustries com Polaris Sales Inc 2100 Hwy 55 Medina MN 55340 U S A Part No 9921837 Revision 01 Printed in U S A WELCOME Thank you for purchasing a Polaris vehicle and welcome to our world wide family of Polaris owners We proudly produce an exciting line of utility and recreational products e Snowmobiles e All terrain vehicles ATVs e Quadricycles Tractors e RANGER utility vehicles e Victory motorcycles Always follow the instructions and recommendations in this manual The manual contains
23. Remove the cap and add the recommended fluid as needed DO NOT use brake fluid 6 Maintain the fluid level 76 between the minimum and maximum marks Do not over fill ADC Fluid Reservoir MAINTENANCE Active Descent Control ADC Fluid Fluid Change l 2 TIP Ae 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 per formance of the system Fill the reservoir to the maximum line with fresh ADC fluid Remove the protective caps from the bleeder valves Slowly loosen one of the valves turn counter clockwise and allow fluid and trapped air to flow from the fitting Close the valve when clean fluid begins to flow Repeat this step for the remaining valve IMPORTANT Close the bleeder valves before the reservoir fluid level drops below the minimum fill line Adding fluid to an empty 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 Te 8 Torque the valves to 80 in Ibs 9 N m Reinstall the valve caps Add fresh ADC
24. Switches 2c os cad eee ences ease 20 22 AXA SWIC e a he 22 Engine Stop Switch 21 Hazard Warning 22 Headlight Switch 21 iu 6 91 eee eres eee eran 22 Light Switch 21 Main Key Switch 2l Master Light Switch 20 Mode Reverse Override Switch 20 Turn Signal 22 T Vat ON 2 AA 94 Throttle Cable Freeplay 87 Throttle CV Cl is fis alan eects 82 Ute 23 Tire Tread Depth n n nananana 88 T WAN CS od ocala parece sa hades 88 89 Wheel Installation 89 Wheel Nut Torque 88 Wheel Removal 89 Toe Alignment 40 3 oaxaw ee cea bie 84 Towing a Disabled Vehicle 115 Towing Capacities 58 Towing Loads 58 59 Training Safety 7 Transmission a an anaana 27 Transmission Oil 72 73 Transporting the Vehicle 115 Turn Signal Lamp Front 94 Turn Signal Lamp Rear 94 Turn Signal Switch 22 Turning Around ona Hill 50 51 Turning the Vehicle 45 INDEX V Vehicle Identification Numbers 6 Vehicle Immersion 98 99 NIN ee 26 seb ae ceed ho Nr cdhe a 6 W Warning Symbols 4 Washing the Vehicle 109 110 Wheel Installation 89 Wheel Nut Torque Specifications 88 Wheel Removal 89 131
25. ack Storage Box Capacity 90 lbs 41 kg Rear Rack Capacity 180 Ibs 82 kg Rear Hitch Tongue Capacity 120 lbs 54 4 kg Rear rack capacity and tongue weight not to exceed 180 lbs 82 kg Rear Hitch Towing Capacity 1225 lbs 555 kg on level ground Front Hitch Tongue Capacity 85 Ibs 39 kg Front rack capacity and tongue weight not to exceed 90 Ibs 41 kg Front Hitch Towing Capacity 850 Ibs 386 kg Overall Wit Overall Height 48 in 122 cm Wheelbase 50 5 in 128 cm Ground Clearance 11 in 28 cm Minimum Turning Radius 65 in 165 cm unloaded Ignition Timing 10 1 BTDC idle Spark Plug NGK BKRO6E Spark Plug Gap 035 0 0 0 004 in 0 9 0 0 0 1 mm Lubrication System Dry Sump Driving System Type Automatic PVT Polaris Variable Transmission Front Suspension MacPherson strut with 8 2 21 cm travel Rear Suspension Progressive rate with 9 5 24 cm travel 116 SPECIFICATIONS Sportsman 500 EFI Tractor w E Z Shift H L N R P Brake Hand All wheel hydraulic disc All wheel hydraulie dise Brake Parking Transmission park lock and hydraulic lock all wheel Clutching EBS Models Altitude Shift Drive Clutch Driven Weight Spring Clutch Spring Meters 0 1800 10 WH Blue Green White Yellow EBS Feet 0 6000 PN 5630710 PN 7041157 PN 7041635 PN 5131674 1800 3700 10 RH Blue Green White Yellow EBS 6000 12000 PN 5630709 PN 7041157 PN 7041635 PN 5131674 EBS models require n
26. ain Plug Torque Torque iL Drive Demand Drive LT 275 ml 11 14 N m 15 N m Unit Premium Fluid Use the recommended fluid Use of other fluids may result in improper operation of components See page 118 for the part numbers of Polaris products Maintain the fluid level at Fill Plug the bottom of the fill hole Fill Level threads Fluid Level 1 Position the vehicle on a level surface 2 Place the transmission in PARK 3 Remove the fill plug Add the recommended demand drive fluid as needed 5 Reinstall the fill plug Torque to specification 74 MAINTENANCE Front Gearcase Demand Drive Fluid Fluid Change 1 Position the vehicle on a level surface 2 Place the transmission in PARK 3 Remove the fill plug 4 Remove the drain plug Drain the fluid into a drain pan 5 Clean the drain plug 6 Reinstall the drain plug Torque to specification See page 74 Add the recommended fluid 8 Reinstall the fill plug Torque to specification 9 Check for leaks 10 Discard used oil properly I3 MAINTENANCE Active Descent Control ADC Fluid The ADC fluid reservoir is located under the front box The reservoir cap is yellow We recommend the use of Polaris ADC Fluid See page 118 for the part numbers of Polaris products Fluid Level 1 Position the vehicle on a level surface 2 Open the front box cover 3 Open the access door 4 View the fluid level in the reservoir 5
27. and reposition the seat tabs in one of the rear seat base slots Make sure the seat is securely installed before operating Backrest Adjustment Loosen the backrest knobs on each side of the backrest mount and slide the backrest forward or rearward to the desired posi tion Tighten the knobs securely Measure Preload shown with seat removed Height Adjustment Slots Backrest Knobs 29 FEATURES AND CONTROLS Steering Lock Lock the steering to prevent unauthorized use or theft of the vehicle A The handlebars are locked in the fully turned position when the steering is locked Always unlock the steering before starting the engine 1 Turn the handlebars to the full right position The handlebars may also be locked in the full left position 2 Insert the steering lock key and turn it clockwise Remove the key 3 Place the steering lock keys in a safe place The lock must be replaced if the keys are lost 4 Reverse the procedure to unlock the steering Hitches See page 116 for hitch weight capacities Front Hitch Use the front hitch for vehicle recovery or towing only Do not use the front hitch for any other purpose Always remove the front hitch before operating in forward gear Rear Hitch Hitch specifications may differ from vehicle capacity specifications Do not exceed the hitch and towing capacities specified for this vehicle See page 116 Use the rear hitch for towing a trailer See pag
28. ar protective riding gear See page 8 Perform the pre ride inspection See page 41 Sit upright Keep your feet on the footrests Keep both hands on the handlebars Start the engine and allow it to warm up Apply the brakes Shift the transmission into gear Check your surroundings and determine your path of travel Release the brakes Slowly squeeze the throttle lever toward the handlebar to begin driving Drive slowly Practice maneuvering and using the throttle and brakes on level surfaces Turning the Vehicle l Before turning activate a turn signal to alert oth ers of your intentions Activate the left signal before a left turn Acti vate the right signal before a right turn Steer in the direction of the turn leaning your upper body to the inside of the turn while sup porting your weight on the outer footrest Use the same leaning tech nique for turning in reverse Never turn quickly when carrying cargo Practice making turns at slow speeds before attempting to turn at faster speeds Always follow the procedures outlined in this manual for turning Never turn sharply at excessive speeds which can lead to vehicle overturn OPERATION 45 OPERATION Driving Uphill 25 Maximum Whenever traveling uphill follow these precautions l oS a E a 9 Always move the 4X4 switch to ADC 4X4 before ascending or descending a hill See page 30 Avoid ste
29. aris 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 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 e Avoid the use of automotive products some of which can scratch the finish of your vehicle e 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 110 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 1f 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
30. chine in the crate or without proper dealer set up will void your warranty coverage 123 WARRANTY WARRANTY COVERAGE AND EXCLUSIONS LIMITATIONS OF WARRANTIES AND REMEDIES The Polaris limited warranty excludes any failures that are not caused by a defect in material or workmanship This warranty does not cover accidental damage normal wear and tear abuse or improper handling This warranty also does not cover any vehicle that has been altered structurally modified neglected improperly maintained used for rac ing or used for purposes other than for which it was manufactured or for any damages which occur during trailer transit or as a result of unauthorized service or the use of unauthorized parts In addition this warranty does not cover physical damage to paint or finish stress cracks tearing or puncturing of upholstery material corrosion or defects in parts components or the vehicle due to fire explosions or any other cause beyond Polaris control This warranty does not cover the use of unauthorized lubricants chemicals or fuels that are not compatible with the vehicle The exclusive remedy for breach of this warranty shall be at Polaris exclusive option repair or replacement of any defective materials or components or products THE REMEDIES SET FORTH IN THIS WARRANTY ARE THE ONLY REMEDIES AVAILABLE TO ANY PERSON FOR BREACH OF THIS WARRANTY POLARIS SHALL HAVE NO LIABILITY TO ANY PERSON FOR INCIDENTAL CONSEQUENTIAL OR SPE
31. ck 67 MAINTENANCE Engine Oil Oil and Filter Change 1 Position the vehicle on a level surface 2 Place the transmission in PARK 3 Start the engine Allow it to idle for 30 seconds 4 Stop the engine 5 Clean the area around the drain plug 6 Place a drain pan under the oil tank 7 Remove the drain plug 8 Drain the oil New Sealing Washer A Hot oil may result in serious burns Do not allow hot oil to contact skin 9 Clean the drain plug Reinstall the drain plug with a new sealing washer gt gt 10 Torque to specification See page 66 ja Co 68 MAINTENANCE Engine Oil Oil and Filter Change 11 12 13 14 15 16 17 18 TIP 19 Disconnect the lower oil deliv ery hose and remove the screen fitting from the oil tank Clean the fitting Seal the fitting threads with LOCTITE PST 505 or PTFE seal tape Reinstall the screen fitting and rotate the fitting clockwise a e minimum of 2 1 2 turns into the Alignment M M ie tank threads Continue to rotate the fitting until the nipple of the fitting aligns with the mark on the tank Do not over tighten Maxi mum torque for the screen fitting is 34 N m Reattach the oil line Place towels under the oil filter Using an oil filter wrench turn the filter counterclockwise to remove it Clean the filter sealing area on the crankcase Lubricate the filter o ring Check to make sure t
32. de or on the left side 1f the vehicle is pointed straight uphill Stay uphill of the vehicle and turn the handlebars full left Squeeze the brake lever to release the parking brake Slowly release the brake lever and allow the vehicle to roll around to your right until it s pointing across the hill or slightly downward OPERATION Turning Around on a Hill K Turn 9 Lock the hydraulic parking brake 10 Remount from the uphill side Keep your weight uphill 11 Apply the foot brake 12 With the transmission still in forward start the engine 13 Squeeze and release the brake lever to release the parking brake 14 Release the foot brake and drive slowly downhill Control speed with either the hand or foot brake until the vehicle is on level ground A Always follow the procedures outlined in this manual for climbing hills Avoid climbing hills steeper than 25 A Always follow the procedures outlined in this manual for braking if you stall or roll backwards while climbing a hill Never back down a hill 51 OPERATION Driving Through Water Follow these procedures when driving through water l 2 3 4 52 Check water depth and current before crossing Choose a crossing where both banks have gradual inclines Drive slowly Avoid rocks and obstacles Avoid operating in water deeper than the bottom of the footrests If it s unavoidable travel slowly balance your weight carefully and avoid sudden movem
33. depending on your preference To reset the service interval l 2 3 36 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 FEATURES AND CONTROLS Instrument Cluster Rider Information Center Diagnostic Mode Miles Kilometers toggle The display in the tripmeter and odometer can be changed to display either standard or metric units of measurement 1 Enter the diagnostic mode 2 Toggle to the screen that displays either kilometers KM or miles 3 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 Downloading Codes The EFI diagnostic mode is for informational purposes only Please see your Polaris dealer for all major repairs See page 39 for Blink Codes and Failure Descriptions Use the follow ing procedure to download blink codes failure codes from the EFI module 1 Place the transmission in PARK Stop the engine Turn the key switch to
34. diator Coolant A Escaping steam can cause severe burns Never remove the pressure cap while the engine is warm or hot l 2 Open the front box cover Open the access door Remove the radiator pressure cap If coolant is not visible slowly add coolant through the radiator filler neck Reinstall the pressure cap Use of a non standard pres sure cap will not allow the recovery system to function properly Contact your dealer for the correct replacement part Radiator Cap Secure the access door and box cover 19 MAINTENANCE Brake Fluid Check brake fluid levels for both brake systems before each ride Always maintain brake fluid at the recommended level Do not overfill The brakes should feel firm when they re applied Spongy or weak brakes may indicate a fluid leak or low fluid level A low fluid level may also mean that brake pads are worn and need to be replaced Do not operate the vehicle with spongy or weak brakes See your dealer for ser vice A Operating the Tractor with a spongy brake can result in loss of braking which could cause an accident Never operate the Tractor with spongy feeling brakes If the fluid level is low add DOT 4 brake fluid only See page 118 for the part numbers of Polaris products A 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 Under n
35. dlebars in the direction of the skid and shifting your body weight forward 6 Never apply the brakes during a skid NOTICE Severe damage to drive train may occur if 4X4 is engaged while the wheels are spinning Engage 4X4 when the wheels have traction 54 OPERATION Driving Over Obstacles Always check for obstacles before operating in a new area Be alert Watch the terrain Use extra caution Never operate over large obstacles Avoid hazards such as logs rocks and low branches oS Parking on an Incline Avoid parking on an incline If it s unavoidable follow these precautions 1 Stop the engine 2 Place the transmission in PARK 3 Always block the rear wheels on the downhill side 55 OPERATION Driving in Reverse Follow these precautions when operating in reverse 1 Always check for obstacles or people behind the vehicle before backing Avoid backing downhill Drive slowly Apply the brakes lightly for stopping Avoid turning at sharp angles Never open the throttle suddenly oe R ie Do not use the override switch unless additional power is required for vehicle movement Use with caution 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 56 OPERATION Hauling Cargo A Overloading the vehicle or carrying or towing cargo improperly can alter vehicle handling and may ca
36. e 42 damage Allow the engine to warm up for several minutes before operating Position the vehicle on a level surface Place the transmission in PARK or neutral Sit on the vehicle Apply the brakes Move the engine stop switch to RUN Do not press the throttle while starting the engine Turn the ignition key past the PARKING LIGHTS ON position to engage the starter Activate the starter for a maxi mum of five seconds releasing the key when the engine starts If the engine does not start release the starter and wait five seconds Repeat steps 7 and 8 until the engine starts OPERATION Cold Weather Operation Internal engine condensation increases as outside temperatures decrease If the vehicle is used year round check the oil level fre quently A rising oil level could indicate condensation in the bottom of the oil tank which can lead to engine damage Any condensation must be drained Always operate the engine long enough to reach operating temperature which reduces condensation See your Polaris dealer for engine heater kits which provide quicker warm ups and easier starting in cold weather PVT Operation When To Use Low Range and High Range Condition Range to Use Operating at speeds less than 11 km h Low Towing heavy loads Low Operating in rough or rugged terrain Operating at speeds greater than 11 km h 43 OPERATION Driving Procedures U9 O p at a ne 44 We
37. e or accidental starting eS A Always unlock the steering before starting the engine See page 26 A Hot components can cause serious burns and fire Do not touch hot exhaust system components Always keep combustible materials away from the exhaust system For more information about Tractor safety contact an authorized Polaris Tractor dealer or visit the Polaris web site at www polarisindustries com 16 SAFETY Safety Labels and Locations Warning labels have been placed on the vehicle for your protection Read and follow the instructions on each label carefully If a label becomes illegible or comes off contact your Polaris dealer to purchase a replacement Replacement safety labels are provided by Polaris at no charge The part number is printed on the label The following pages repeat the information found on each label General Alert Multi Lingual Before you operate this vehicle read the owner s manual 7173025 Hill Operation Hitch Alert e Never operate this vehicle on HILLS steeper than 25 degrees 25 e To prevent flip over on hilly terrain when going up or down use throttle and brakes gradually 7175814 Age 16 Alert Hill Operation and Hitch Alert SAFETY Safety Labels and Locations Reverse Override Alert aD Rack mrX NIGO Clutch Warnin WE Rack g ae Cover Alert Warning re aK J cc hei joy p No Passenger Sak Warning PA Rn i A l a F
38. eak In 40 PVT Operation serna dee 43 PVT SyS ectares aa 102 103 R Reverse Operation 56 Reverse Override Switch 20 Rider Information Center 32 39 Rider Salet yoco tiaia hones 10 16 Riding Gear 0 005 8 9 S Safety Decals Age 16 Alert 17 Safety Labels 17 19 No Passenger Warning 19 4X4 AWD Switch 18 Clutch Cover Alert 19 General Alert 17 Hill Operation Alert 17 Rack Warning 19 Reverse Override Alert 18 Tire Pressure Load Alert 18 130 S Salety rainine asuen r ele ies T Seara e EE E E EN 25 Backrest Adjustment 25 Height Adjustment 23 Load Adjustment 25 Seat Removal 00 25 Service Interval Programming 36 Severe Use raspiu een atoms 61 Side Panel Removal 86 Side nilli rars kees eee sees 48 Signal Words 2 2 60260442 lt 0ad buds 4 Spark Arrestor 100 101 Spark Arrestor Requirements 60 Spark Plug Inspection 96 Spark Plug Recommendations 96 Spark Plug Torque Specification 96 Spark PMCS 2224 cee obese Cees 96 97 Specifications 116 117 Spring Adjustment Rear Shock 85 Starting the Engine 42 Steering Assembly 85 Seerne LOCK 2 cag k Bick natn eee 26 STOA DE nos do nee atees 109 114 Storage Lipset eke ike ds 112 114
39. earcase Lube Demand Drive LT 9 3 oz 275 ml See page 74 Premium Fluid Polaris ADC Fluid See page 76 Polaris Premium U Joint Grease fittings 3 Lube pumps maximum every 800 km before long periods of stor age or after pressure washing or submerg ing Front Prop Shaft Yoke 65 MAINTENANCE Engine Oil Oil Recommendations Always change the oil filter whenever changing oil Polaris recommends the use of Polaris PS 4 PLUS Performance Syn thetic 2W 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 2W 50 oil Follow the manufacturer s recommendations for ambient tempera ture operation NOTICE Mixing brands or using a non recommended oil may cause serious engine damage Always use a recommended oil Never substitute or mix oil brands Oil Specifications Lubricant Capacity Drain Plug Torque a 4 PLUS Performance 1 9 liters 19 23 N m Synthetic 2W 50 4 Cycle Oil 66 MAINTENANCE Engine Oil Oil Level 1 Position the vehicle on a level surface 2 Place the transmission in PARK 3 Start the engine Allow it to idle for 30 seconds 4 Stop the engine 5 Remove the dipstick Wipe it dry with a clean cloth 6 Reinstall the dipstick completely 7 Remove the dipstick and check the oil level Add oil as needed Maintain the oil level in the safe range Do not overfill Safe Range aS 8 Reinstall the dipsti
40. eath Engine Stop Switch Engine The engine will not start or run when Stop Switch the switch is in the OFF position X OFF STOP W RUN Light Switch High Low Beam Use the light switch to change the headlights from high beam to low beam The master light switch must be on to operate the headlights High Beam A Low Beam 21 FEATURES AND CONTROLS Switches 4X4 Switch Use the 4X4 switch to engage ADC 4X4 4X4 or 2X4 See page 28 Hazard Warning Switch Hazard Warning Push the hazard warning _ Switch switch to cause all turn signal lights to flash simultaneously Use this an emergency or other Situation requiring caution Turn Signal Switch lt g gt Push the toggle switch either left or right to activate the corresponding turn signal light The indicator on the pod will also flash Return the toggle to the center position and push it inward to end the signal Turn Signal Horn Switch Switch Horn Switch box Press the horn switch to sound the horn 22 FEATURES AND CONTROLS Mirrors Use the mirrors to assist in traffic maneuvers Always check and adjust the mirrors before driving the Tractor Throttle Lever A Failure to check or maintain proper operation of the throttle system can result in an accident if the throttle lever sticks during operation Check the lever for proper operation before starting the engine Check occasionally during operation
41. ents Maintain a slow and steady forward motion Do not make sudden turns stops or throttle changes Wet brakes may have reduced stopping ability Dry the brake pads by driving slowly and applying the brakes lightly several times until braking action 1s normal OPERATION Driving Through Water If your vehicle becomes fully immersed and it s impossible to take it to a dealer before starting it follow the steps described on page 98 Have the vehicle serviced by your dealer promptly A Always follow the procedures outlined in this manual for driving through water Never drive through deep or fast flowing water ole oe A If the vehicle stops while fully submerged major engine damage can result if the machine is not thoroughly inspected Take the vehicle to your dealer before starting the engine 53 OPERATION Driving on Slippery Surfaces Sideways Turn in skid direction of skid D SF pry CO C Peel FT TOOoysps C C 3 2 Sof x C a A Always follow the procedures outlined in this manual for operating on slippery or loose surfaces Use extra caution Always avoid skidding or sliding Whenever driving on slippery or loose surfaces such as wet trails gravel snow or ice follow these precautions 1 Slow down before driving onto slippery surfaces Engage 4X4 before wheels begin to lose traction Be alert Watch the trail Avoid quick sharp turns AA Correct a skid by turning the han
42. ep hills 25 maximum Avoid hills with slippery or loose surfaces Keep both feet on the footrests Shift body weight uphill Drive straight uphill Proceed at a steady rate of speed to avoid stalling Be alert Be prepared to take emergency action This may include dismounting quickly Never open the throttle suddenly or make sudden gear changes 10 Never go over the top of a hill at high speed 46 OPERATION Driving Uphill If all forward speed is lost Keep your weight uphill If the vehicle begins rolling downhill never apply engine power Never apply the brakes aggressively while rolling backwards l 2 3 4 Always follow the procedures outlined in this manual for climbing hills Avoid climbing hills steeper than 25 Always follow the procedures outlined in this manual for braking if you stall or roll backwards while climbing a hill Never back down a hill Apply the brakes gradually When fully stopped lock the hydraulic parking brake Dismount on the uphill side or on the left side 1f the vehicle is pointed straight uphill Use the K turn to turn around See page 50 A A 47 OPERATION Driving on a Sidehill Sidehilling Avoid crossing the side of a hill sidehilling if possible If sidehilling 1s necessary follow these precautions Slow down Avoid hills with slippery or loose surfaces Avoid crossing the sides of steep hills Shift your weight uphill Keep your fee
43. er function that limits the vehicle s speed to approximately 11 14 km h Refer to page 20 for additional information Speedometer Needle Speedometer Rider Information Center P amp LARIS NOTICE High water pressure may damage vehicle components Wash the vehicle by 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 31 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 diag nosis 1 Gear Indicator This 3 4 5 6 indicator displays gear shifter position H High Gear L Low Gear N Neutral R Reverse Gear P Park 2 2 4X4 Indicator This indicator illuminates when the 4X4 switch is 1 on either ADC 4X4 or 4X4 Engine Hour Display Indicator Service Interval Diagnostic Mode Indicator Odometer Tachometer Tripmeter Hour Meter Clock
44. ervoir 4 Remove the cap and add the recommended fluid as needed 5 Maintain the fluid level between the minimum and maximum marks Do not Brake Fluid overfill Reservoir Maximum A ae 6 Reinstall the reservoir cap 7 Reinstall the seat 82 MAINTENANCE Brakes The front and rear brakes are hydraulic disc brakes activated by apply ing the foot brake The handlebar brake is also hydraulic Both brake systems are self adjusting Brake Inspections Perform the following checks to keep the brake systems in good operat ing condition Check more often 1f brakes are used heavily under normal operation 1 Always keep brake fluid at an adequate level See page 80 2 Check the brake systems regularly for fluid leaks 3 Check the brakes for excessive travel or spongy feel 4 Check the friction pads for wear damage and looseness Replace the pads when the friction material is worn to 1 mm 5 Check the security and surface condition of the disc 83 MAINTENANCE Toe Alignment A Do not attempt to adjust alignment All steering adjustments should be performed by an authorized Polaris dealer Use the following procedure to check the toe alignment of the vehicle The recommended toe alignment is 3 6 mm toe out 1 Position the vehicle on a level surface A 2 Place the handlebars in a Stand straight ahead position 3 Tie a length of string String between two stands as ae shown in
45. es 57 59 for procedures Rear Hitch Specifications 1021 M Steel 1008K Steel Main Pin and Receiver Pin 26 FEATURES AND CONTROLS Hitches Hitch Installation Removal 1 Release the wire lock from the 12 7 mm pin and remove the pin 2 Install the hitch to the receiver 3 Install the 12 7 mm pin through the bore of both the receiver and the hitch Secure the wire lock Make sure the hitch assembly is secure at that the wire lock is properly engaged over the pin 4 Toremove the hitch release the wire lock remove the hitch rein stall the pin to the receiver and secure the wire lock Step 1 Step 2 Step 3 Automatic Transmission Gear Selector The transmission gear selector is located Gear on the right side of the vehicle es selector High Gear P Low Gear Neutral Reverse Park Whenever the vehicle is left unattended always place the transmission in PARK The transmission is locked when it s in PARK NOTICE Shifting gears with the engine speed above idle or while the vehicle is moving can cause transmission damage Stop the vehicle release the throttle and move the shift lever to the desired gear See your dealer if you experience any shifting problems PRAN Fuel Tank Cap Remove the fuel tank cap to add fuel to the fuel tank Use either leaded or unleaded gasoline with a minimum pump octane of 87 Do not use E 85 fuel 27 FEATURES AND CONTROLS All Wheel Drive 4X4 System The All Wheel Dr
46. ew setting will not be locked into the memory 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 4X4 coil only on models with switchable 4X4 This screen is for informa tional 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 1s for informational purposes only Please see your dealer for all major repairs Programmable service interval When the hours of engine operation equal the programmed service interval setting the wrench icon will flash for 5 seconds each time the engine is started When this feature is enabled it provides a convenient reminder to perform routine maintenance See page 36 The service interval is programmed at 50 hours at the factory 35 FEATURES AND CONTROLS Instrument Cluster Rider Information Center Diagnostic Mode Programmable service interval To enable or disable the service interval l 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
47. flush any debris from the radiator fins NOTE High pressure washers can deform the radiator fins and reduce cooling efficiency 122 WARRANTY LIMITED WARRANTY Polaris Industries Inc 2100 Highway 55 Medina MN 55340 gives a TWO YEAR LIMITED WARRANTY on all components of the Polaris Tractor against defects in material or workmanship This warranty covers the parts and labor charges for repair or replacement of defective parts which are covered by this warranty This warranty begins on the date of purchase This warranty is transferable to another consumer during the warranty period through a Polaris dealer REGISTRATION At the time of sale the Warranty Registration Form must be completed by your dealer and submitted to Polaris within ten days Upon receipt of this registration Polaris will record the registration for warranty THE PURCHASER MUST COMPLETE A QUADRICYCLE SAFETY TRAINING COURSE PROVIDED BY THE DEALER IN ORDER TO HAVE VALID WARRANTY ON THE VEHICLE No verification of reg istration will be sent to the purchaser as the copy of the Warranty Registration Form will be the warranty entitlement If you have not signed the original registration and received the customer copy please contact your dealer immediately NO WARRANTY COV ERAGE WILL BE ALLOWED UNLESS YOUR TRACTOR IS REGISTERED WITH POLARIS Initial dealer preparation and set up of your vehicle is very important in ensuring trou ble free operation Purchasing a ma
48. ged Place the battery in the bat tery holder 2 With conventional batteries install the battery 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 A 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 3 On conventional batteries coat the terminals with dielectric grease or petroleum jelly 4 Connect and tighten the red positive cable first Connect and tighten the black negative cable last 5 Install the battery cover if equipped Secure the battery hold down strap 6 Verify that cables are properly routed Cables should be safely tucked away at the front and rear of the battery 105 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 Bat tery 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 per
49. he o ring is in good condition wv FQ Install the new oil filter After the filter ae contacts the crankcase surface turn it 1 2 ES turn by hand Approximately one cup of engine oil will remain in the crankcase To drain remove the drain plug on the lower right side of the crank case The sealing surfaces on the drain plug and crankcase should be clean and free of burrs nicks or scratches Reinstall the drain plug Torque to 19 N m 69 MAINTENANCE Engine Oil Oil and Filter Change 20 Remove the dipstick 21 Add 1 9 liters of recommended oil TIP If the sump is not drained add about 1 6 liters initially 22 Reinstall the dipstick 23 Place the transmission in PARK 7 24 Prime the oil pump using the procedure f on page 71 R 25 Stop the engine Check for oil leaks 26 Check the oil level Add oil as needed f Maintain the oil level in the safe range Do aes not overfill 27 Reinstall the dipstick 28 Discard used oil and filter properly Safe Range Add Oil Safe 70 Engine Oil Oil and Filter Change Oil Pump Priming This priming procedure must be performed whenever the oil hose connection between the oil tank and pump inlet has been disconnected 1 Clamp the vent line 5 cm from the oil tank between the end of the oil tank vent fitting and the vent line s pressure relief slit 2 Start the engine Allow it to idle for 10 20 seconds MAINTENANCE Tank 5 cm l
50. hes Belt Break in the clutches and belt by operating at slower speeds during the break in period as recommended Pull only light loads Avoid aggres sive acceleration and high speed operation during the break in period 40 OPERATION Pre Ride Checklist Ensure proper operation Ensure proper operation Ensure proper level Inspect lubricate if necessary Inspect lubricate if necessary Steering steering lock Unlock the steering ensure free oper ation Inspect condition and pressure Wheels fasteners Inspect ensure fastener tightness Frame nuts bolts fasteners Inspect ensure tightness Fuel and oil Ensure proper levels Coolant level if applicable Ensure proper level Coolant hoses if applicable Inspect for leaks Throttle Ensure proper operation Ensure operation Ensure proper operation Adjust for best side rear vision Drain deposits whenever visible Headlamp Check operation apply Polaris dielec tric grease when lamp is replaced Brake light taillight Check operation apply Polaris dielec tric grease when lamp is replaced Riding gear Wear approved helmet goggles and protective clothing ADC Fluid Ensure proper level Front Hitch Remove the front hitch if installed 83 oN NNI ON o 00 0 O Od NO Oo ON COO O1 MNI NI DP ao O 93 94 N O 41 OPERATION Starting the Engine NOTICE Operating the vehicle immediately after starting could cause engin
51. htening 88 IMIMETSION 52 cx ee hediccowauwek 99 Immersion Maintenance 98 Instrument Cluster 31 39 K INGY SWIM cue eee hot hes 21 Keim 2232 ierte ntenni 50 51 L Light Switch High Low Beam 21 Light Switch Master 20 Eiphit soci era seraricies ee ote a leases tee 92 94 Brake Light lt 222 964 distinu 94 Front Turn Signal 94 Headlight Lamp 93 High Beam Adjustment 92 Position Light Lamp 93 Rear Turn Signal 94 Vea OU see ee cee ania 94 Low Range Use 43 Lubrication Guide 65 M Maintenance Chart 61 64 IEDR OTS ciaras eegen ee Site Os eg a 23 Mode Switch i4 lt c 0c4 setreee ens 20 Modifications t 0 5 ened s vip iaa 7 N Noise Emission Control System 60 O Oil NOMS eenean eent 66 71 Transmission 72 73 129 INDEX O Oil Change EOSen ater aed Y 68 71 Transmission 73 Oil Level NOME tsa te eae inns area aes 67 Transmission 72 Oil Pump Priming 71 Oil Recommendations Eneme Oilissa eiea 66 Transmission I2 Override Switch 20 P Parking Brake nnnnnnnaaa 24 Parking on an Incline 55 Periodic Maintenance Chart 61 64 Polaris Product List 118 Polishing the Vehicle 110 Position Light Lamp 93 Pre Ride Checklist 41 PVT Br
52. ightly off the ground Be sure the storage area is well ventilated 3 Cover the vehicle with a genuine Polaris cover Do not use plastic or coated materials They do not allow enough ventilation to prevent condensation and may promote corrosion and oxidation 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 Tractor use Please see your Polaris dealer 114 MAINTENANCE Transporting the Vehicle Follow these procedures when transporting the vehicle l 2 Stop the engine Place the transmission in PARK Secure the fuel cap oil cap and seat Remove the key to prevent loss during transporting Always tie the frame of the Tractor to the transporting unit securely with suitable straps or rope Do not attach tie straps to the front A arm bolt pockets racks or handlebars Towing a Disabled Vehicle If towing the vehicle is necessary shift the transmission into neutral for better mobility and to prevent damage to the belt Always attach the tow rope to the frame of the Tractor 115 SPECIFICATIONS Sportsman 500 EFI Tractor Maximum Weight Capacity 420 lbs 191 kg includes operator cargo acces sories tongue weight Dry Weight 775 Ibs 352 kg Front R
53. in reverse order 94 MAINTENANCE Fuse Replacement Speedometer If the engine stops or will not start or if you experience other electrical fail ures a fuse may need replacement Spare fuses are provided in a compart ment on the top of the access door 1 Open the front box cover 2 Open the access door 3 Remove the suspect fuse from the fuse panel Install a new fuse with the same amperage 4 Secure the access door 5 Secure the box cover 95 MAINTENANCE Spark Plugs Spark Plug Recommendations Refer to the specifications section beginning on page 116 for the recom mended spark plug type and gap for your vehicle Torque spark plugs to specification Plug Condition Torque Specification New Spark Plug 12 15 N m Previously Installed Spark Plug 23 27 N m 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 plug for correct color Normal Spark Plug The normal insulator tip 1s tan or brown There will be few combustion deposits The electrodes are not burned or eroded This indicates the proper type and heat range for the engine and the service The tip should not be white A white insulator tip indicates overheating caused by use of an improper spark plug or incorrect throttle body adjustments Wet Fouled Spark
54. in the RPM from day to day may be normal because of changes in humidity temper ature and elevation Clock Mode The clock displays time in a 12 hour format To reset the clock see page 33 FEATURES AND CONTROLS Instrument Cluster Rider Information Center Diagnostic Mode The wrench icon will display when the gauge is 1n 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 l 2 3 4 5 Turn the key switch off and wait 10 seconds Lock the parking brake Place the transmission in neutral Hold the mode reverse override button and turn the key switch on Release the switch as soon as the display is activated Use the mode button to toggle through the diagnostic screens Clock Screen To reset the clock l 2 3 34 Enter the diagnostic mode Toggle to the clock screen Press and hold the mode button until the hour display 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 When the desired hour is displayed wait approximately four sec onds until the minute display flashes Use the same procedure to reset the minutes When the display stops flashing the mode has been set Do not turn the key switch off until the display stops flashing or the n
55. increase when steering is turned full left or right Readjust cable freeplay if this occurs 87 MAINTENANCE Tires A 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 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 116 for recom mended tire type size and pressure Tire Tread Depth Always replace tires 3mm when tread depth is worn to 3 mm or less 7 SS Front Wheel Hub Tightening Front wheel bearing tightness and spindle nut retention are critical com ponent operations All service must be performed by your authorized Polaris dealer Wheel Nut Torque Specifications Check the wheel nut torques occasionally and when they ve been loos ened for maintenance service Nut Torque 122 N m 2 Piece Flange Nut O 37 N m N 88 MAINTENANCE Tires Wheel Removal Installation l 2 10 Position the vehicle on a level surface Place the transmission in PARK Loosen the wheel nuts slightly Place a suitable stand under the footrest frame to raise the wheel slightly off the ground Remove the wheel nuts Remove the wheel Place the wheel on the hub Install the wheel nuts finger tight
56. ing a Polaris Tractor e Never operate this vehicle without proper instruction Take a training course e This vehicle is an ADULT VEHICLE ONLY Operation is prohibited for anyone under 16 years of age e This vehicle is approved for OFF ROAD TOWING ONLY Operating a Tractor trailer combination on public roads is prohibited See your Polaris dealer about configuring the vehicle to be certified to tow a trailer on road 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 Key Number Vehicle Model Number Frame VIN Engine Serial Number Key Number SAFETY Safety Training When you purchased your new Tractor your dealer offered a hands on safety training course You were also provided with printed materials that explain safe operating procedures Review this information on a regular basis If you purchased a used Polaris Tractor from a party other than a Polaris dealer please request free safety training from any authorized Polaris dealer As the operator of the vehicle you are responsible for your personal safety the safety of others and the protection of ou
57. iod and will automatically charge the battery if the voltage drops below a pre determined point See page 118 for the part numbers of Polaris products Battery Fluid Conventional Battery Check the battery fluid level often Maintain the fluid level between the o o upper and lower level marks Add only distilled water Tap water contains minerals that are harmful to a battery 106 MAINTENANCE Battery Battery Charging Conventional Battery 1 Remove the battery from the vehicle to prevent damage from leak ing or spilled electrolyte during charging See page 105 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 105 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 multime
58. ive system is 4D controlled by the 4X4 switch o AN ADC 4X4 When the switch is on ADC 4X4 the ADC system allows engine braking to all four wheels when the vehicle descends a hill or incline Always move the 4X4 switch to ADC 4X4 before ascending or descending a hill See page 30 4X4 When the switch is on 4X4 the vehicle is in 4X4 and the 4X4 indicator light in the instrument cluster will be on When in 4X4 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 4X4 The override switch allows activation of 4X4 in reverse if the 4X4 switch is on See page 20 2X4 When the switch is on 2X4 the vehicle is in two wheel drive at all times 28 FEATURES AND CONTROLS All Wheel Drive 4X4 System Engaging 4X4 The 4X4 switch may be turned on or off while the vehicle is moving 4X4 will not engage until engine speed is below 3100 RPM 4X4 remains engaged until the switch is turned off There is no limit to the length of time the vehicle may remain in 4X4 If the switch is turned off while the demand drive unit is engaged it will not disengage until the rear wheels regain traction Engage 4X4 before getting into situations where maximum traction is needed If the rear wheels are spinning release the throttle before switching
59. lebar to apply the all wheel brakes If the rear wheels begin to skid or slide while using the brake reduce lever pressure Parking Brake 1 Place the transmission in PARK 2 Squeeze the brake lever toward the han dlebar Push the parking brake lock for ward to engage the lock Release the brake lever 3 To release the parking brake lock squeeze and release the brake lever A Operating the vehicle while the parking brake is engaged could result in an accident and serious injury or death Always release the parking brake lock before operating 24 FEATURES AND CONTROLS Load Adjuster Seat Seat Load Adjustment Adjust the seat spring for the comfort of a lighter or heavier operator Reach under the rear rack to access the adjuster Tighten the spring for heavier riders Loosen the spring for lighter rid ers Use the following table to determine the best preload measurement for rider weight Measure preload between the adjuster plate and the lower spring retainer Preload Up 1039 Kg 39 94 Ko Over 94 kg Driver s seat type Seat One e11 78 764 2006 96 2056 00 Seat Removal Lift the latch bar at the rear of the seat to release the latch Tilt the seat slightly rear ward to disengage the seat tabs from the rear seat base slots Remove the seat Make sure the seat is securely installed before operating Seat Height Adjustment To raise or lower the seat remove the seat
60. lts to 14 17 N m then torque the rear two bolts A gap of up to 3 mm will remain at the rear of the clamp blocks Rear Spring The rear shock absorber spring 1s adjusted by rotating the adjuster either clockwise or counterclockwise to increase or decrease spring tension Adjuster 85 MAINTENANCE Side Panel Removal 1 Remove the seat 2 Grasp the rear of the side panel near the rear cab 3 With a firm motion pull the panel outward to disengage the side panel from the grommet 4 Pull the panel downward and rearward to remove it Footwell Removal 1 Remove the six screws on 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 Rivets 86 MAINTENANCE Throttle Cable Freeplay Adjust throttle cable freeplay at the handlebar 1 Locate the throttle cable adjuster at the handlebar 2 Squeeze the end of the rub ber boot and slide it far enough to expose the end of the inline cable adjuster Boot 3 Loosen the adjuster lock nut Lock Nut Adjuster 4 Rotate the boot to turn the adjuster until 1 6 3 2 mm of freeplay is achieved at the thumb lever Move the throt tle lever back and forth while A adjusting 5 Tighten the lock nut 6 Squeeze the end of the rubber boot and slide it over the cable adjuster to its original position 7 Engine RPM should not
61. nditions which could result in loss of control of the vehicle OPERATE ONLY WITH STABLE AND SAFELY ARRANGED LOADS When handling off centered loads that cannot be centered securely fasten the load and operate with extra caution Always attach the tow load to the hitch point designated for your vehicle USE EXTREME CAUTION when operating with loads that extend over the rack sides Stability and maneuverability may be adversely affected causing the vehicle to overturn TOWING is approved OFF ROAD ONLY Operating a Tractor trailer combination on public roads is prohibited TOWING SPEED should never exceed 16 km h Never exceed 8 km h when towing loads in rough terrain while cornering or while ascending or descending hills 57 OPERATION Hauling Cargo Always read and understand the load distribution warning labels on the vehicle Never exceed the weight capacities specified for this vehicle Towing Loads Towing is approved OFF ROAD ONLY Operating a Tractor trailer combination on public roads 1s prohibited See your Polaris dealer about configuring the vehicle to be certified to tow a trailer on road Do not tow any trailer on a grade steeper than 15 e Use the front hitch for vehicle recovery or towing only Always remove the front hitch before operating in forward gear e The combination of rear rack cargo weight and tongue weight must not exceed the rear rack capacity The total load operator accessories cargo and
62. ng your Polaris vehicle clean will not only improve its appearance but it can also extend the life of various components 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 1 Use a professional type washing cloth cleaning the upper body first and the lower parts last 2 Rinse with clean water frequently 3 Dry surfaces with a chamois to prevent water spots Washing Tips e Avoid the use of harsh cleaners which can scratch the finish e Do not use a power washer to clean the vehicle e Do not use medium to heavy duty compounds on the finish e 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 109 MAINTENANCE Cleaning and Storage Washing the Vehicle If a high pressure water system is used for cleaning not recommended exercise extreme caution The water may damage components and could remove paint and labels Avoid directing the water stream at the follow Ing items e Wheel bearings e Radiator e Transmission seals e Brakes e Cab and body panels e Labels and decals e Electrical components and wiring If an informational or graphic label becomes illegible or comes off con tact your Pol
63. o helix spring adjustment 117 POLARIS PRODUCTS Part Number 2870797 2876244 2876245 2873602 2873603 2876144 Active Descent Control ADC Fluid 2876257 2870465 2871323 2871534 2871312 2871322 2871423 2871460 2871518 287155 2871326 2870652 2872188 Description 118 TROUBLESHOOTING Drive Belt Wear Burn Possible Cause Solution Driving onto a pickup or Use low range tall trailer in high range Starting out going up a Use low range or turn around using the K turn see page steep incline 50 Driving at low RPM or Drive at a higher speed or use low range more frequently ground speed 5 11 kmh Insufficient warm upat Warm the engine at least 5 minutes With the transmission low ambient tempera in neutral advance the throttle to about 1 8 throttle in tures short bursts 5 to 7 times The belt will become more flex ible and prevent belt burning Slow easy clutch engage Use the throttle quickly and effectively ment Towing pushing at low Use low range only RPM low ground speed Utility use plowing Use low range only Stuck in mud or snow Shift the transmission to low range Carefully use fast aggressive throttle application to engage clutch WARNING Excessive throttle may cause loss of control and vehicle overturn Climbing over large objects from a stopped position Belt slippage from water Dry out the PVT See page 103 Inspect clutch seals for or snow ingestion into the damage if re
64. ormal 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 A 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 accident or severe injury After opening a bottle of brake fluid always discard any unused portion 80 MAINTENANCE Brake Fluid Hand Brake Indicator The master cylinder is Master Window located on the left handle bar Maintain the fluid level 6 mm below the top edge of the master cylinder Do not overfill 1 Position the vehicle on a level surface Make sure the handlebars are straight 2 View the fluid level through the indicator win dow eye 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 3 Add the recommended fluid as needed Do not overfill 81 MAINTENANCE Brake Fluid Foot Brake The foot brake fluid reservoir is located under the seat 1 Position the vehicle on a level surface Remove the seat 3 View the fluid level in the res
65. ouled or defective spark plug s Inspect clean and or replace spark plug s Worn or defective Worn or defective spark plug wires plug wires See See your dealer See your dealer Possible Lean Fuel Cause Solution Low or contaminated fuel Add or change fuel clean the fuel system Clogged fuel filter Replace filter Kinked or plugged fuel vent line Inspect and replace if equipped Possible Rich Fuel Cause Solution Fuel is very high octane Replace with lower octane fuel Stopping starting without adequate Allow engine to warm up before operat warm up na and or SIQEpine Clogged air filter Inspect and clean or a 121 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 if equipped Water is present in fuel Replace with fresh recommended fuel Old or non recommended fuel Replace with fresh recommended fuel Fouled or defective spark plug s Inspect clean and or replace spark plug s Loose ignition connections Other mechanical failure See your dealer Overheated engine Clean radiator screen and core clean engine exterior see your dealer Engine Overheating Possible Cause Solution Debris lodged in screen 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
66. peated leaking occurs PVT system Clutch malfunction See your Polaris dealer Slippage from failure to Always warm up the belt by operating below 40 km h for warm up belt 1 5 km 8 km or more when temperature is below freez ing Poor engine performance Check for fouled plugs or foreign material in gas tank or fuel lines See your dealer Wrong or missing belt Install the recommended belt Improper break in Always break in a new belt and or clutch See page 40 119 TROUBLESHOOTING Engine Does Not Rotate Possible Cause Solution Low battery voltage Recharge the battery to 12 8 VDC Loose battery connections Check all connections and tighten Loose solenoid connections Check all connections and tighten Engine Rotates Fails to Start Possible Cause Solution Low battery voltage Recharge the battery to 12 8 VDC Mechanical failure See your dealer Engine Backfires Possible Cause Solution Weak spark from spark plug Inspect clean and or replace spark plug s Incorrect spark plug gap or heat range Set gap to specs or replace plugs Oid or non tecommended el O Check all connections and tighten 120 TROUBLESHOOTING Engine Pings or Knocks Possible Cause Solution Poor quality or low octane fuel Replace with recommended fuel 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 Solution F
67. plug the exhaust outlet Wear protective gloves Lightly tap on the exhaust pipe with a rubber mallet while repeat ing step 5 If particles are still suspected to be in the muffler elevate the rear of the vehicle 30 cm higher than the front Block the wheels Place the transmission in PARK Repeat steps 5 to 7 until no more particles are expelled Stop the engine Allow the arrestor to cool Reinstall the arrestor plug and remove the exhaust outlet cover or plug 101 MAINTENANCE PVT System A 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 e Always follow all recommended maintenance procedures See your dealer as outlined in the owner s manual e This PVT system is intended for use on Polaris products only Do not install it in any other product e Always make sure the PVT housing is securely in place during operation 102 MAINTENANCE PVT System PVT Drying There may be some instances when
68. ps The filter is effective with the arrow pointing in either direction NOTICE Operation of your vehicle without a breather filter can cause engine damage 91 MAINTENANCE Lights High Beam Adjustment The headlight beam can be adjusted slightly upward or downward 1 Position the vehicle on a level surface The headlight should be approximately 7 6 m from a wall 2 Place the transmission in PARK 3 Measure the distance from the floor to the center of the headlight and make a mark on the wall at the same height Include rider weight on the seat when measuring 4 Start the engine Turn the head Screw light switch to high beam 5 Observe the headlight aim on the Vae ig N wall The most intense part of pt the headlight beam should be 5 cm below the mark on the wall 6 Tighten or loosen the lower headlight screws to adjust the beam upward or downward or to the left or right 92 MAINTENANCE Lights A Poor lighting can result in loss of control or an accident Lights become dirty during normal operation Wash the headlights and taillights frequently Hot components can cause serious burns to skin Do not service the headlamps until they ve cooled Headlight Position Light Lamp Replacement When servicing a halogen lamp do not touch the lamp with bare fingers Oil from your skin leaves a residue causing a hot spot that will shorten the life of the lamp Hold the plastic part of the lamp
69. r environment Read and understand your owner s manual which includes valuable informa tion about all aspects of your vehicle including safe operating proce dures Ride responsibly Know all laws and regulations concerning the opera tion of this vehicle in your area Equipment Modifications The warranty on your Polaris Tractor may be terminated if any equip ment has been added or if any modifications have been made that increase speed or power The addition of certain accessories including but not limited to mowers blades tires sprayers and large racks may change vehicle handling Use only Polaris approved accessories Know their function and effect on the vehicle SAFETY Safe Riding Gear Always wear protective clothing to reduce the chance of injury Eye Protection Helmet Gloves Helmet Always wear a helmet that meets or exceeds established safety stan dards Approved helmets in the USA and Canada bear a U S Department of Transportation DOT label Approved helmets in Europe Asia and Oceania 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 9909 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
70. s subjected to water mud etc mee drive 3 Inspect clean replace worn F ava e Front wheel 1600 Inspect replace as needed bearings E Brake Brake fluid 3200 Change every two years soon fluid 200 carn 2000 3200 Change every two years be os a 24 M 3200 Replace every 2 years more often under severe use Spark arrestor 300 36M 4800 Clean out out ae adjustment a periodically adjust when parts are replaced Headlight aim Adjust as needed gt Perform these procedures more often for vehicles subjected to severe use E Emission Related Service m Have an authorized Polaris dealer perform these services 64 MAINTENANCE Lubrication Guide Check and lubricate all components at the intervals outlined in the Peri odic Maintenance Chart beginning on page 61 Items not listed in the chart should be lubricated at the General Lubrication interval The a arms and upper 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 provided for additional lubrication at the user s discretion Engine Oil Brake Fluid Transmission Oil Demand Drive Fluid Front Gearcase ADC Fluid Front Prop Shaft Yoke Lube Capacity at Fluid Change PS 4 PLUS Performance 2 qt 1 9 See page 66 Synthetic 2W 50 DOT 4 Only a a See page 80 Polaris AGL Synthetic 32 oz 948 ml See page 72 G
71. severe use E Emission related service E Have an authorized Polaris dealer perform these services Perform all services at whichever maintenance interval is reached first Maintenance Interval whichever comes first Hours Calendar Kilometers Pre Ride fet Make adjustments as need F P eee ed See Pre Ride Checklist Front suspension PreRide len page ai Rear suspension Preni pies Preige Brake tuidtevel Prewide Brake lever Pre Ride Footbrake Prena Brake system Pene Passenger seat Pre Ride lock out Wheelsifasteners Prene FrameTasteners Pene gt Enone oreve Prene Air filter pre filter Daily Inspect clean often replace as needed Air box sediment Daily Drain deposits when visible tube Coolant Daily Check level daily change coolant every 2 years ADC fluid Daily Check level daily add as needed Headlight taillight Daily Check operation apply dielectric grease if replacing lamps 62 MAINTENANCE Periodic Maintenance Chart Maintenance Interval whichever comes first Pp vea cE reek eee Sa aT replace as needed FE e reek A pad wear Ba Monthly enna periodically Battery 20 Monthy 320 Check terminals clean test e drive ear 2s Monthly 400 T level Inspect level change yearly yearly la E gearcase oil Monthly O A A level change yearly if equipped gt Transmission oil _ oil 25 Monthy 40
72. 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 Riding pants with kneepads and a jersey with shoulder pads provide the best protection SAFETY Rider Safety A WARNING Serious injury or death can result if you do not follow the instructions and procedures listed here and throughout this manual A Read and understand all warnings cautions and operating procedures in this manual and on the safety labels before operating the Tractor Never operate a Tractor without proper instruction Take a training course Beginners should receive training from a certified instructor Contact an authorized Polaris Tractor dealer or visit the Polaris web site at www polarisindustries com Never permit others to operate the Tractor unless they have read and understand this manual and all product labels and have completed a certified safety training course A Never allow anyone under 16 years of age to operate this vehicle A Gasoline is highly flammable and explosive under certain conditions e Use extreme ca
73. t gt Clamp Pressure Relief Slit 3 Remove the vent line clamp If the line is bled properly you should hear a rush of air If you do not hear a rush of air repeat the priming procedure 71 MAINTENANCE Transmission Oil Maintain the oil level at the bottom of the fill plug hole threads Use the recommended oil See page 118 for the part numbers of Polaris products Transmission Oil Recommendations Lubricant Oil Change Fill Plug Drain Plug Capacity Torque Torque Premium AGL Synthetic 948 ml 30 N m 30 N m Gearcase Lubricant Transmission Oil Level 1 Position the vehicle on a level surface 2 Place the transmission in PARK 3 Remove the fill plug Check the oil level Add the recommended oil as needed Do not overfill 5 Reinstall the fill plug Torque to specification J2 MAINTENANCE Transmission Oil Transmission Oil Change l 2 8 9 10 Check for leaks 11 Discard used oil properly Position the vehicle on a level surface Place the transmission in PARK Remove the fill plug Remove the drain plug Drain the oil into a drain pan Clean the drain plug Reinstall the drain plug Torque to specification See page 72 Add the recommended oil See page 72 Reinstall the fill plug Torque to specification See page 72 73 MAINTENANCE Front Gearcase Demand Drive Fluid Fluid Recommendations Gearcase Lubricant Capacity Fill Plug Dr
74. t on the footrests ot a oe a If the vehicle begins to tip quickly turn the front wheel downhill if possible or dismount on the uphill side immediately A Always follow the procedures outlined in this manual for crossing the side of a hill Never attempt to turn the Tractor around on any hill until you ve mastered on level ground the turning technique outlined in this manual 48 OPERATION Driving Downhill When driving downhill follow these precautions l AR a i 2 Always follow the procedures outlined in this manual for driving downhill and for braking on hills Always move the 4X4 switch to ADC 4X4 before ascending or descending a hill See page 30 Avoid steep hills 25 maximum Avoid hills with slippery or loose surfaces Never drive downhill at high speed Slow down Drive straight downhill Avoid driving downhill at an angle which can cause the vehicle to pitch sharply to one side Shift your weight rearward Apply the brakes slightly to aid in slowing A 49 OPERATION Turning Around on a Hill K Turn If the vehicle stalls while climbing a hill never back it down the hill Use the K turn to turn around 50 Stop the vehicle Keep your weight uphill Always move the 4X4 switch to ADC 4X4 before ascending or descending a hill See page 30 Lock the hydraulic parking brake Leave the transmission in forward gear Turn the engine off Dismount on the uphill si
75. ter to measure DC voltage 107 MAINTENANCE Battery Battery Charging Sealed Battery 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 battery voltage is 12 8 or greater When using an auto matic charger refer to the charger manufacturer s instructions for recharging When using a constant current charger use the follow ing guidelines for recharging A 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 Always verify battery condition before and 1 2 hours after the end of charging State of Charge Time Voltage Using constant current Charge charger standard amps specified on top of battery 100 12 8 13 0 volts None check at 3 None required mos from date of manufacture 50 75 12 0 12 5 volts Needs charge 5 11 hours 25 50 11 5 12 0 volts Needs charge At least 13 hours verify state of charge 0 25 11 5 volts or less Needs charge with At least 20 hours desulfating charger 75 100 12 5 12 8 volts May need slight 3 6 hours charge if no charge given check in 3 months 108 MAINTENANCE Cleaning and Storage Washing the Vehicle Keepi
76. the ON position 2 Turn the key switch off and on three times in less than five seconds The word WAIt will appear on the screen 37 FEATURES AND CONTROLS Instrument Cluster Rider Information Center Downloading Codes 3 The Check Engine icon will blink once pause then blink twice blink code 12 to begin the diagnostic sequence The EFI module is now searching for blink codes If a code exists the Check Engine icon will flash the code 4 Count the number of times the Check Engine icon flashes Example For the two blink codes 42 and 36 the Check Engine icon will flash 4 times pause then flash 2 times code 42 then pause longer blink 3 times pause and blink 6 times code 36 5 A code 61 will signal the end of the sequence If no blink codes are found only codes 12 and 61 will appear during the sequence The word WAIt will remain on the screen through this entire process Code Definitions Open Load There is a break in the wires that lead to the item listed in the chart injector fuel pump etc or the item has failed Short to Ground The wire is shorted to ground between the electronic control unit and the item listed in the chart Shorted Load The wires leading to the item listed in the chart are shorted together or the item has shorted internally Short to Battery The wire leading from the item listed in the chart to the electronic control unit is shorted to a wire at battery voltage
77. the plug or install a new plug MAINTENANCE Torque to specification See page 96 Attempt to start the engine If necessary repeat the drying procedure Have the vehicle serviced by your dealer promptly whether you succeed in starting it or not If water has been ingested into the PVT follow the procedure on page 103 for drying out the PVT 99 MAINTENANCE Spark Arrestor A Failure to heed the following warnings while servicing the spark arrestor 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 arrestor while the system is hot Allow components to cool sufficiently before proceeding Occasionally the spark arrestor may accumulate carbon which can restrict the exhaust if left unattended Purge the spark arrestor 1 Position the vehicle on a level surface 2 Place the transmission in PARK 3 Remove the arrestor clean out plug from the bottom of the muffler Start the engine 5 Quickly squeeze and release the throttle lever several times to purge car bon from the system 100 MAINTENANCE Spark Arrestor 6 10 11 If carbon comes out of the exhaust cover or
78. the illustration Position the stands so that the string is flush with the side of the rear tire TIP If available you may use a long straight edge instead 2 gt of string 4 Measure the distance gt from the string to the rim at the front 1 and rear 2 of the front rim The rear measurement should be 2 3 mm more than the front mea surement on each side of the vehicle to obtain the recommended 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 ser vice 84 MAINTENANCE Steering Assembly Check the steering assembly of the vehicle periodically for loose nuts and bolts If loose nuts and bolts are found see your Polaris dealer for service before operating the vehicle Handlebar Adjustment The handlebars can be adjusted for rider preference A 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 Follow the adjustment procedures exactly or see your Polaris dealer for service 1 Remove the upper headlight pod Loosen the four handlebar bolts 3 Adjust the handlebar to the desired height 4 Besure the handlebars do not con tact the gas tank or any other part of the machine when turned fully to the left or right 5 Torque the front two bo
79. to 4X4 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 29 FEATURES AND CONTROLS Active Descent Control ADC System The ADC system allows engine braking to all four wheels when the vehicle 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 e The 4X4 switch must be in the ADC 4X4 position e Vehicle speed must be 24 km h or less e The throttle must be closed throttle lever released e 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 e The 4X4 switch is moved out of the ADC 4X4 position e Vehicle speed exceeds 24 km h e The throttle is open throttle is applied e The transmission is shifted to neutral or park 30 FEATURES AND CONTROLS Instrument Cluster The instrument cluster senses vehicle speed from the transmission In addition to showing vehicle speed the speedometer needle flashes when a warning condition exists The instrument cluster measures distance in miles or kilometers as well as hours of operation It also includes a reverse speed limit
80. ual for braking if you stall or roll backwards while climbing a hill Never back down a hill See page 50 A Always follow the procedures outlined in this manual for operating over obstacles See page 55 A Always follow the procedures outlined in this manual for operating on slippery or loose surfaces Use extra caution Always avoid skidding or sliding See page 54 A Always follow the procedures outlined in this manual for driving through water Never drive through deep or fast flowing water See page 52 14 ele ee SAFETY Rider Safety A Always follow the procedures outlined in this manual for driving in reverse See page 56 A Always use the size and type of tires specified for your vehicle Maintain the proper tire pressure Never modify a Tractor through improper installation or use of accessories A Never exceed the stated load capacity for your vehicle Cargo must be properly distributed and securely attached Reduce speed and follow the instructions in this manual for carrying cargo or towing Allow a greater distance for braking 15 SAFETY Rider Safety Never operate the Tractor on a frozen body of water Operating on paved surfaces may affect the handling and control of the Tractor and could result in loss of control Avoid sudden turns or swift movement of the handlebars A Always remove the ignition key when the vehicle is not in use to prevent unauthorized us
81. use loss of control or brake instability Always follow these precautions when hauling cargo Read and understand the load distribution warnings listed on the vehicle warning labels NEVER EXCEED THE MAXIMUM WEIGHT CAPACITY of the vehicle When determining the weight you are adding to the vehicle include the weight of the operator accessories loads in the racks and the load on the trailer tongue The combined weight of these items must not exceed the maximum weight capacity REDUCE SPEED AND ALLOW GREATER DISTANCES FOR BRAKING WHEN HAULING CARGO OR TOWING Use extreme caution when applying brakes Avoid situations that require backing downhill When operating over rough or hilly terrain reduce speed cargo and towed load to maintain stable driving conditions DO NOT BLOCK THE FRONT HEADLIGHT BEAM when carrying loads on the front rack CARRY LOADS AS LOW ON THE RACK AS POSSIBLE Carrying a load high on the rack raises the center of gravity of the vehicle and creates a less stable operating condition Reduce load weight when cargo is high Secure off centered loads that cannot be centered and operate with extra caution CARRYING A LOAD on only one rack may cause the vehicle to overturn Split the load between the front rack and rear rack with 1 3 in the front and 2 3 in the back Do not exceed load capacities See specifications beginning on page 116 SECURE ALL LOADS BEFORE OPERATING Unsecured loads can create unstable operating co
82. ution whenever handling gasoline e Refuel with the engine stopped Refuel outdoors or in a well ventilated area e Never fill a fuel container while it s on the vehicle Static electricity between the rack and container could cause a spark e Do not smoke or allow open flames or sparks in or near the area where refueling is performed or where gasoline is stored Do not overfill the tank Do not fill the tank neck e If gasoline spills on your skin or clothing immediately wash it off with soap and water and change clothing A Engine exhaust contains poisonous carbon monoxide and can cause loss of consciousness resulting in severe injury or death Never run an engine in an enclosed area 10 SAFETY Rider Safety A Never carry a passenger on this vehicle A Always wear an approved helmet that fits properly Wear eye protection goggles or face shield gloves boots long sleeves and long pants A Never consume alcohol or drugs before or while operating a Tractor A Never operate at excessive speeds Travel and turn at speeds appropriate for the terrain visibility operating conditions and your experience 11 SAFETY Rider Safety A Always inspect your Tractor before each use to verify that it s in safe operating condition Follow the inspection and maintenance procedures outlined in this manual See page 41 A Keep both hands on the handlebars Keep both feet on the footrests A Alwa
83. weight on hitch must not exceed the maximum weight capacity of the vehicle Capacities Maximum Towed Load Level Ground 557 kg 386 kg Maximum Vertical Hitch Weight 55 kg 39 kg 58 OPERATION Hauling Cargo Towing Loads A Using an improper hitch or exceeding the maximum tongue weight capacity can result in serious damage to the vehicle and will void your warranty Never install a hitch longer than 10 cm Never install auto motive accessories on your Polaris Tractor Always install Polaris approved or equivalent accessories designed for Tractor use 1I lt Maximum 10 cm 59 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 Spark Arrestor Your Polaris vehicle has a spark arrestor that was designed for on road and off road operation It 1s required that this spark arrestor remain installed and functional when the vehicle is operated 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 spark ignition system complies with USA requirements Canadian ICES 002 and EMC requirements of European directives 97 24 EC and 2004 108 EC
84. ys travel slowly when operating on unfamiliar terrain Use extra caution A Always follow the procedures outlined in this manual for turning See page 45 Never turn sharply at excessive speeds which can lead to vehicle overturn A Ifa Tractor has been involved in an accident always have an authorized Polaris dealer inspect the entire vehicle for possible damage including but not limited to brake throttle and steering systems 12 SAFETY Rider Safety A Never attempt jumps or other stunts A Always follow the procedures outlined in this manual for driving on hills See page 46 Never operate on hills too steep for the Tractor or for your abilities Practice on smaller hills before attempting larger hills Avoid climbing hills steeper than 25 Always move the 4X4 switch to ADC 4X4 before ascending or descending a hill A Always follow the procedures outlined in this manual for driving downhill and for braking on hills See page 49 A Always follow the procedures outlined in this manual for crossing the side of a hill See page 48 Never attempt to turn the Tractor around on any hill until you ve mastered on level ground the turning technique outlined in this manual A Use the front hitch for vehicle recovery or towing only Always remove the front hitch before operating in forward gear See page 26 13 SAFETY Rider Safety A Always follow the procedures outlined in this man

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