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Polaris 600 Switchback Offroad Vehicle User Manual

1. 110 C Camber Adjustment 136 Care Oii wd c Cis rm ss eh 65 67 Cargo Loading 64 Caster Adjustment 136 Chrome Wheel Care 131 Cleaning and Storage 129 134 Clock Setting Time 55 Clothing ue REA 13 Clutching 500 EFI 000 145 700 EFE 1 gh amore 147 800 EFI 00 149 158 C Cold Weather Operation 63 Consumer Product Safety 20 Coolant Bottle 102 Coolant Radiator 103 Cooling System 102 103 Corrosion Removal Chrome 131 Crankcase Emission Control System 84 D Demand Drive Capacities 99 Demand Drive Fluid 100 Differential Switch 39 Disengaging Active Descent Control 49 Drive Belt Wear Burn 139 Drivetrain Break In 61 Driving Downhill 75 Driving in Reverse 82 83 Driving on a Sidehill 74 Driving on Slippery Surfaces 72 Driving Over Obstacles 80 Driving Procedures 68 Driving Through Water 78 79 Driving Uphill s suus 73 Driving with a Passenger 70 71 E Electromagnetic Interference 84 Emissions Limited Warranty 155 Engaging 4X4 00 0 48 Engaging Active Descent Control 49 Engine Break In 61 Engine Fogging 133 Engine Oil
2. Transmission Automatic EBS Engine Braking System with E Z Shift H L N R P Gear Reduction Low 23 91 1 Gear Reduction Reverse 21 74 1 Gear Reduction High 828 1 Drive Ratio Front 3 82 1 Tires Pressure Front 25x8 12 5 psi Tires Pressure Rear 25x11 12 5 psi Brakes Front Single Control Hydraulic Disc Brakes Rear Single Control Hydraulic Disc Brake Auxiliary Foot Activated Hydraulic Disc Brake Parking Hydraulic lock all wheel Headlight 1 Single Beam on Headlight Pod 50 watt 2 Single Beam on Bumper 37 5 watt Taillights 1 826wats Brake Light 26 9 watts Instrument Cluster LCD Clutching EBS Models Altitude Shift Drive Clutch Driven Helix Weight Spring Clutch Spring Meters 0 1800 21 74 66 56 33 Feet 0 6000 PN 5632117 Red White Red BA500 PN 7043349 PN 3234452 EB 1800 3700 21 70 5 6000 12000 PN 5632106 PN 3234604 NOTE EBS models require no helix spring adjustment 149 WARRANTY LIMITED WARRANTY Polaris Sales Inc 2100 Highway 55 Medina MN 55340 gives a SIX MONTH LIM ITED WARRANTY on all components of the Polaris All Terrain Vehicle ATV against defects in material or workmanship Polaris also gives a one year limited warranty on the final drive chain for failure due to defects This warranty covers the parts and labor charges for repair or replacement of defective parts which are
3. 90 97 Engine Stop Switch 38 Equipment Modifications 21 Exhaust Emission Control System 84 Eye Protection 13 F Fluid Active Descent Control 100 101 Brake exe 42 Coolant ss en 102 103 Demand Drive 99 100 Engine Oil 90 F Fluid Change ADC i55 uer ten ane dd 101 Demand Drive 100 Engine Oil 500 93 95 Engine Oil 700 800 96 97 Transmission 99 Fluid Level ADC cx tee uve es UU 101 Brake es de ee ss ae 42 44 Coolant 102 103 Demand Drive 100 Engine Oil 500 91 Engine Oil 700 800 92 Transmission 98 Foot Brake Auxiliary 44 Footwell Removal 106 Fuel Filter 500 EFI 45 Fuel Recommendations 45 Fuel Safety 000 60 Fuel Tank Cap 45 Fuse Replacement 111 G Gear Selector i251 sans ae cde 45 GIOVES n 13 H Hand Brake 104 Handlebar Adjustment 137 Hauling Cargo 64 67 Headlight Housing Replacement 114 Headlight Lamp Replacement 112 Headlight Switch 39 le ete So tes stares eens teen ate goa 12 High Beam Adjustment 113 High Range Use 122 Hub Tightening 107 l Idle RPM Adjustment 138 Immersion Maintenance 118 Instrument
4. 46 Reverse Operation 82 83 Reverse Override Switch 38 Rider Information Center 53 59 Rider Safety 14 37 Riding Gear 12 13 S Safety Decals 6 11 Age 16 Warning 6 Box Warning 11 Clutch Cover Warning 10 Discretionary Warning 6 General Warning 7 Passenger Safety 8 Rack Warning Front and Rear 10 Reverse Override Warning 11 Tire Pressure Load Warning 9 Safety Training 15 Service Interval Programming 57 severe Use oie ales rms 85 Side Panel Removal 106 Sidehiling 0 0 74 Signal Words 16 Spark Arrestor 119 Spark Plug Inspection 116 117 Spark Plug Recommendations 116 Spark Plug Torque Specification 116 Spark Plugs 116 117 Specifications 144 149 Spring Adjustment Rear Shock 136 Starting the Engine 63 Steering Assembly 106 Storage 2 eee eee eee 129 134 Storage Tips 132 134 Switches e cece eee 38 39 4X4 Switch 38 Differential Switch 39 Engine Stop Switch 38 Headlight Switch 39 Main Key Switch 38 Mode Reverse Override Switch 38 Worklight Switch 39 160 T Taillight Lamp Replacement 115 Throttle Body Adjustment
5. 84 Maintenance elles 85 Adjustments L ee 136 Troubleshooting e 139 Polaris Products 143 Specifications 144 Warranty fish ole Siena TOR eRe eee 150 Maintenance Log 000ee0es 156 INDO ii eruta eee ee LA EHE RE 158 KNOW YOUR VEHICLE As the operator of the vehicle you are responsible for your personal safety the safety of others including your passenger and the protec tion of our environment Read and understand your owner s manual which includes valuable information about all aspects of your vehicle including safe operating procedures 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 CER HHH Key Number 700 800 Vehicle Model Number Frame VIN Engine Serial Number Key Number SAFETY Safety Decals and Locations Warning decals have been placed on the ATV for your protection Read and follow the instructions of the decals on the ATV carefully If any of the decals depicted in this manual differ from the decals on your ATV always read and follow the instructions of the
6. 138 Throttle Cable Freeplay Adjustment 138 Throttle Lever 0 40 Mires 26s 5 severe o s ho 107 108 Tire Tread Depth 107 Wheel Installation 108 Wheel Nut Torque 108 Wheel Removal 107 Toe Alignment 105 Towing Capacities 66 Towing Loads 00 66 Training 0 000 15 Transmission 45 Transmission Oil 98 99 Transporting the ATV 135 Turning Around ona Hill 76 77 Turning the Vehicle 69 V Vehicle Identification Numbers 5 Vehicle Immersion 118 MIN egre oer toes ached seer Re pce e 5 Ww Warning Symbols 16 Washing the Vehicle 129 130 Wheel Installation 108 Wheel Nut Torque Specifications 108 Wheel Removal 107 Worklight Lamp Replacement 115 Worklight Switch 39
7. Clean radiator screen and core clean engine exterior see your dealer Engine Overheating Possible Cause Debris lodged in screen Solution Remove and clean the screen Pull on the top portion of the screen then remove the lower portion Plugged Radiator Use a garden hose to flush any debris from the radiator fins NOTE High pres sure washers can deform the radiator fins and reduce cooling efficiency 142 POLARIS PRODUCTS AS Description Engine Lubricant 2870791 Fogging Oil 12 oz Aerosol 2876244 PS 4 PLUS Performance Synthetic 2W 50 4 Cycle Oil qt 2876245 PS 4 PLUS Performance Synthetic 2W 50 4 Cycle Oil gal Gearcase Transmission Lubricants 2873602 Premium AGL Synthetic Gearcase Lubricant qt 95 I 2873603 Premium AGL Synthetic Gearcase Lube gal 3 8 I 2876144 Active Descent Control ADC Fluid 2871653 Premium ATV Angle Drive Fluid 8 0z 237 ml 2872276 Premium ATV Angle Drive Fluid 2 5 gal 9 5 I 2870465 Pump for Gallon 3 8 I Jug 2876251 Demand Drive LT Premium Fluid 8 0z 237 ml Coolant 2871323 60 40 Coolant gal 3 8 2871534 60 40 Coolant qt 95 I Grease Specialized Lubricants 2871312 Grease Gun Kit Premium All Season 2871322 Premium All Season Grease 3 0z 89 ml cartridge 2871423 Premium All Season Grease 14 0z 414 ml cartridge 2871460 Starter Dr
8. without proper training or instruction at speeds too fast for your skills your passenger s skills or the conditions on public roads a collision can occur with another vehicle with more than one passenger passengers affect balance and steering and increase risk of losing control with a passenger under the age of 12 THE OPERATOR MUST ALWAYS use proper riding techniques to avoid vehicle overturns on hills and rough terrain and in turns avoid paved surfaces pavement may seriously affect handling and control reduce speed and use extra caution at all times when carrying a passenger have passenger dismount when conditions require make sure passenger reads and understands this label and passenger safety label LOCATE AND READ OWNER S MANUAL FOLLOW ALL INSTRUCTIONS AND WARNINGS IF OWNER S MANUAL IS MISSING CONTACT A POLARIS DEALER FOR A REPLACEMENT 7173889 SAFETY Safety Decals and Locations Passenger Safety Warning WARNING PASSENGER SAFETY To reduce the risk of SEVERE INJURY or DEATH NEVER CARRY A PASSENGER UNDER AGE 12 NEVER CARRY MORE THAN ONE PASSENGER NEVER RIDE AFTER USING DRUGS OR ALCOHOL NEVER carry a passenger too small to firmly plant feet on footrests and securely grasp hand holds THE PASSENGER MUST ALWAYS Ex ni use an approved helmet and protective gear securely grasp hand holds and plant feet firmly on footrests tell operator to slow down or s
9. Wrong or missing belt Install the recommended belt Improper break in Always break in a new belt and or clutch See page 61 139 TROUBLESHOOTING Engine Doesn t Turn Over Possible Cause Low battery voltage Solution Recharge the battery to 12 8 VDC Loose battery connections Check all connections and tighten Loose solenoid connections Check all connections and tighten Engine Turns Over Fails to Start Possible Cause Out of fuel Solution Refuel cycle key to ON position three times for 5 seconds each then start Clogged fuel filter Replace the filter Water is present in fuel Drain the fuel system and refuel Old or non recommended fuel Replace with fresh recommended fuel Fouled or defective spark plug s Inspect plugs and replace if necessary No spark to spark plug Inspect plugs verify stop switch is on Water or fuel in crankcase Immediately see your Polaris dealer Low battery voltage Recharge the battery to 12 8 VDC Mechanical failure See your dealer Engine Backfires Possible Cause Weak spark from spark plug Solution Inspect clean and or replace spark plug s Incorrect spark plug gap or heat range Set gap to specs or replace plugs Old or non recommended fuel Replace with fresh recommended fuel Incorrectly installed spark plug wires See your dealer Incorrect ignit
10. Operating the ATV with a spongy brake lever can result in loss of braking which could cause an accident Never operate the ATV with a spongy feeling brake lever 41 FEATURES AND CONTROLS Master Cylinder Brake Fluid Check the brake fluid in the master Master Cylinder cylinder before each ride The fluid level can be seen through an indicator window on the top of the master cylinder This eye will appear dark when the fluid level is full When fluid is low the eye will be clear NOTE When checking the fluid level the ATV must be on Indicator level ground with the handle Window bars straight If the fluid level is low add DOT 4 brake fluid only See page 143 for the part numbers of Polaris products A WARNING An over full master cylinder may cause brake drag or brake lock up which could result in serious injury or death Maintain brake fluid at the recommended level Do not overfill A WARNING 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 42 FEATURES AND CONTROLS Parking Brake A WARNING Operating the ATV while the parking brake is engaged could result in an
11. 1 6 I initially 20 Place the transmission in PARK 21 Lock the parking brake 22 Prime the oil pump using the procedure on page 95 Then stop the engine and inspect for leaks 23 Check the oil level Add oil as needed to bring the level to the upper mark on the dipstick 24 Dispose of used filter and oil properly 94 MAINTENANCE Engine Oil Cil and Filter Change 500 EFI Cil Pump Priming This priming procedure must be Tank performed whenever the oil hose connection between the oil tank and pump inlet has been disconnected 1 Clamp or pinch off the vent line approximately 2 5 cm from the oil tank between the end of the oil tank vent fitting and the ae gt Pressure vent line s pressure relief slit Relief Slit 2 Start the engine Allow it to idle for 10 20 seconds 3 Remove the vent line clamp If the line is bled properly you should hear a rush of air indicating that the line is properly primed and ready for operation NOTE f you do not hear air the line has not bled Repeat the priming procedure 95 MAINTENANCE Engine Oil Oil and Filter Change 700 800 EFI A CAUTION Hot oil can cause serious burns to skin Do not allow hot oil to contact skin Always change the oil and filter at the intervals outlined in the Periodic Maintenance Chart beginning on page 85 Always change the oil filter whenever changing oil l 2 Position the vehicle on a level surface
12. Never apply the brakes during a skid Do not operate on excessively slippery surfaces Always reduce speed and use additional caution 72 OPERATION Driving Uphill 15 Maximum Whenever traveling uphill follow these precautions 1 Always move the 4X4 switch to ADC 4X4 before ascending or descending a hill See page 49 Drive straight uphill Avoid steep hills 15 maximum Keep both feet on the footrests Shift body weight uphill Proceed at a steady rate of speed and throttle opening Remain alert and be prepared to take emergency action This may include quick dismounting of the vehicle 8 Ifthe vehicle stalls while climbing a hill never back it down the hill Apply the hand brake If a passenger is on board ask the pas senger to dismount Use the K turn to turn around See page 76 A WARNING Braking and handling are greatly affected when operating in hilly terrain Improper procedure could cause loss of control or overturn and result in serious injury or death Avoid climbing steep hills 15 maximum Use extreme caution when operating on hills and follow proper operating procedures outlined in the owner s manual ur eno exp b 73 OPERATION Driving on a Sidehill Sidehilling A WARNING Improperly crossing hills or turning on hills can result in loss of control or vehicle overturn resulting in severe injury or death Avoid crossing the side of a hill when pos
13. Start the engine Allow it to warm up at idle for two to three min utes Stop the engine Drain Plug Location eieo Clean the area around the drain plug Place a drain pan under the crankcase odf l Remove the drain plug Allow the oil to drain completely TETA to front Install a new sealing washer on the drain plug NOTE The sealing surfaces on drain plug and crankcase should be clean and 8 96 free of burrs nicks or scratches Reinstall the drain plug Torque to 20 ft Ibs 27 Nm MAINTENANCE Engine Oil Cil and Filter Change 700 800 EFI 9 10 11 12 13 14 15 16 17 18 19 20 2 Place shop towels beneath the oil filter Using an oil filter wrench available from your Polaris dealer turn the filter counter clockwise to remove it Using a clean dry cloth clean the filter sealing surface on the crankcase Lubricate the o ring on the new filter with a film of fresh engine oil Check to make sure the o ring is in good condition Install the new filter and rotate it clockwise by hand until the filter gasket contacts the sealing surface then turn it an additional 1 2 turn Remove the dipstick Add two quarts 1 9 I of recommended oil Place the transmission in PARK Lock the parking brake Start the engine Allow it to idle for one to two minutes Stop the engine Check for leaks Check the oil level Add oil
14. The Way Out or visit www polarisindustries com Polaris Sales Inc 2100 Hwy 55 Medina MN 55340 Phone 1 888 704 5290 Part No 9921356 Rev 03 Printed in USA WARNING The engine exhaust from this product contains chemicals known to the State of California to cause cancer birth defects or other reproductive harm A card containing important ATV safety information should be attached to the owner s manual on the next page If you cannot locate this card or if it has been removed please call 1 800 342 3764 for assistance 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 Snowmobiles All terrain vehicles ATVs RANGER utility vehicles Victory motorcycles We believe Polaris sets a standard of excellence for all utility and recre ational vehicles manufactured in the world today Many years of experi ence have gone into the engineering design and development of your Polaris vehicle making it the finest machine we ve ever produced For safe and enjoyable operation of your vehicle be sure to follow the instructions and recommendations in this owner s manual Your manual contains instructions for minor maintenance but information about major repairs is outlined in the Polaris Service Manual and should be performed only by a Factory Certified Master Service Dealer MS
15. accident and serious injury or death Always check to be sure the parking brake is disengaged before operating Locking the Parking Brake l 2 PARK Squeeze and release the brake G e lever two or three times then 0 squeeze and hold Push the parking brake lock forward to engage the lock Release the brake lever To release the parking brake lock squeeze and release the brake lever It will return to its unlocked position Place the transmission in Y wt 9 Important Safeguards The parking brake may relax if left on for a long period of time Always block the wheels to prevent rolling Always block the wheels on the downhill side of the ATV if leaving it parked on a hill Another option is to park the ATV in a sidehill posi tion Never depend on the parking brake alone if the ATV is parked on a hill Always block the wheels to prevent rolling 43 FEATURES AND CONTROLS Auxiliary Foot Brake The auxiliary brake system is intended to be used as a backup for the main brake system Should the main system fail use the auxiliary foot brake NOTE Sincethis is a rear brake only it will not be as effective as the all wheel single lever system A WARNING Aggressively applying the auxiliary brake when backing down a hill may cause rear tipover which could result in serious injury or death Never back down a hill Use caution when applying the auxiliary brake Do n
16. 12 years of age to ride as a passenger on this 2 up ATV 14 SAFETY Rider Safety Safety Training ATV safety training is a top priority for Polaris When you purchased your new ATV your dealer instructed you on the authorized ATV RiderCourse available to you and your eligible family members This training is included in the purchase price of your ATV Polaris strongly encourages you and your eligible family members who will be riding the ATV to take the ATV RiderCourse You were also provided with printed materials that explain safe operating procedures You should review this information on a regular basis If you purchased a used Polaris ATV you can take the ATV RiderCourse by calling ATV Enrollment Express at 800 887 2887 or by visiting www atvsafety org Purchasers of a used Polaris ATV will be charged for this training A Polaris ATV is an off road vehicle Familiarize yourself with all laws and regulations concerning the operation of this vehicle in your area We strongly advise you to strictly follow the recommended maintenance program outlined in your owner s manual This preventive maintenance program is designed to ensure that all critical components on your vehicle are thoroughly inspected at specific intervals 15 SAFETY Rider Safety 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
17. 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 93 Air Filter Air Box 1 Inspect and clean or replace the pre cleaner and air filter See page 109 2 Clean the air box 3 Drain the sediment tube 4 Clean or replace the breather filter if equipped See page 110 Recoil Housing 500 EFI Drain the recoil housing See page 117 132 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 85 Demand drive unit front gearcase ADC fluid ADC models change every two years Rear gearcase if equipped Transmission Brake fluid change every two years and any time the fluid looks dark or contaminated Coolant test strength fill Fog the Engine l Treat the fuel system with Polaris Carbon Clean Follow the instruc tions on the container Start the engine Allow it to idle for several minutes so the Carbon Clean reaches the injectors Stop the engine Remove the spark plug and add 2 3 tablespoons of engine oil To access the plug hole use a section of clear 1 4 hose and a small plastic squeeze bottle filled with the pre measured amount of oil NOTE Do this carefully If you miss the plug hole oil will drain from the spark plug cavity into the hole at the front
18. Cluster 52 59 K Key Switch 000 38 K TD fn 22225 6 ESReS ems 76 77 INDEX L EC 11 they 112 115 Headlight Housing 114 Headlight Lamp 112 High Beam Adjustment 113 Low Beam Adjustment 113 Lower Headlamp Replacement 115 Taillight Brakelight Worklight 115 Low Range Use 122 Lubrication Guide 89 M Maintenance Chart 85 88 Master Cylinder 42 Mode Switch 05 38 Modifications 21 N Noise Emission Control System 84 0 Oil Engine 2p elm 90 97 Transmission 98 99 Oil Change Engine 500 EFI 93 95 Engine 700 800 EFI 96 97 Transmission 99 Oil Level Engine 500 EFI 91 Engine 700 800 EFI 92 Transmission 98 Oil Pump Priming 500 EFI 95 Oil Recommendations 90 Operation on Public Lands 84 Override Switch 38 P Parking Brake 43 Parking on an Incline 81 Passenger Seat 50 51 Periodic Maintenance Chart 85 88 Polaris Product List 143 Polishing the Vehicle 130 Pre Ride Checklist 62 PVT Break In 61 PVT Dryint sic crt e eum 122 PVT System 120 122 159 INDEX R Recoil Housing 500 EFI 117 Recoil Starter 500 EFI
19. NOTE Do not hold the throttle wide open for more than 10 seconds 5 Allow the engine RPM to settle to idle speed then shift the trans mission to the lowest available range 6 Test for belt slippage If the belt slips repeat the process 7 Take the vehicle to your dealer for service as soon as possible 122 MAINTENANCE Battery Your ATV may have either a sealed battery which requires little mainte nance or a conventional battery A sealed battery can be identified by its flat covers on the top of the battery A conventional battery has six filler caps on the top of the battery Conventional 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 A WARNING Battery electrolyte is poisonous It contains sulfuric acid Serious burns can result from contact with skin eyes or clothing Antidote External Flush with water Internal Drink large quantities of water or milk Follow with milk of magnesia beaten egg or vegetable oil Call physician immediately Eyes Flush with water for 15 minutes and get prompt medical attention Batteries produce explosive gase
20. Position Sensor High 25 Gear Sensor Signal 31 System Voltage Low 31 System Voltage High 36 Ignition Coil A Prim Sec Circuit Malfunction Open Load Short to Ground 36 Ignition Coil A Prim Sec Circuit Malfunction Shorted Load Short to Battery 37 Ignition Coil B Prim Sec Circuit Malfunction Open Load Short to Ground 37 Ignition Coil B Prim Sec Circuit Malfunction Shorted Load Short to Battery 41 Air Temp Sensor Low Voltage 41 Air Temp Sensor High Voltage 42 Engine Coolant Temp Low Voltage 42 Engine Coolant Temp High Voltage 44 Crank Position Sensor Circuit Fault 45 Barometric Pressure Manifold Air Pressure Sensor Low 46 Barometric Pressure Manifold Air Pressure Sensor High 47 IAC Stepper Motor Open Load 47 IAC Stepper Motor Short to Ground 51 Injector Circuit Malfunction Cyl 1 Open Load Short to Ground 51 Injector Circuit Malfunction Cyl 1 Shorted Load Short to Battery 52 Injector Circuit Malfunction Cyl 2 Open Load Short to Ground 52 Injector Circuit Malfunction Cyl 2 Shorted Load Short to Battery 55 MIL Circuit Open Load Short to Ground 55 MIL Circuit Shorted Load Short to Battery 56 Fuel Pump Open Load Short to Ground 56 Fuel Pump Shorted Load Short to Battery 58 Fan Circuit Open Load Short to Ground 58 Fan Circuit Shorted Load Short to Battery 59 ADC Open Load Short to Ground 59 ADC Shorted Load Short to Battery 63 Starter Enable Open Load Short to Ground 63 Starter Enable Shorted Load Short to Battery 72 Gear Sensor
21. Signal 73 4X4 Open Load Short to Ground 73 4X4 Shorted Load Short to Battery 74 Rear Differential Enable Open Load Short to Ground 74 Rear Differential Enable Shorted Load Short to Battery 61 END SEQUENCE 59 OPERATION Fuel Safety A WARNING Gasoline is highly flammable and explosive under certain conditions Always exercise extreme caution whenever handling gasoline Always refuel with the engine stopped and outdoors or in a well ventilated area Do not smoke or allow open flames or sparks in or near the area where refueling is performed or where gasoline is stored Do not overfill the tank Do not fill the tank neck If gasoline spills on your skin or clothing immediately wash it off with soap and water and change clothing Never start the engine or let it run in an enclosed area Engine exhaust fumes are poisonous and can cause loss of consciousness or death in a short time A WARNING The engine exhaust from this product contains chemicals known to cause cancer birth defects or other reproductive harm Operate this vehicle only outdoors or in well ventilated areas 60 OPERATION Break In Period The break in period for your new Polaris ATV 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 is as important as following the proce dures for a proper break in Careful treatment of a new
22. around 3000 RPM This is well above the engagement speed of 1200 1400 RPM However in high range at 3 MPH 5 km h the engine would be running at only 1500 RPM Whenever operating this close to the engagement speed the engine may be running at a speed too low to provide the pinch needed to prevent belt slip Belt slip is responsible for creating the excessive heat that destroys belts wears clutch components and causes outer clutch covers to fail By switching to low range while operating at low ground speeds the air temperature in the clutch cover is reduced by almost 160 degrees Reducing the temperature inside the clutch cover extends the life of the PVT components belt cover etc 121 MAINTENANCE PVT System When To Use Low Range and High Range Condition Range to Use Operating at speeds less than 7 MPH 11 km h Low Towing heavy loads Low Operating in rough terrain swamps mountains etc Low Operating at speeds greater than 7 MPH 11 km h High PVT Drying There may be some instances when water is accidently ingested into the PVT system Use the following instructions to dry it out before operat ing 1 Position the vehicle on a level surface 2 Remove the drain plug Allow the water to drain completely Rein stall the drain plug 3 Start the engine Place the transmission in PARK Apply varying throttle for 10 15 seconds to expel the moisture and air dry the belt and clutches
23. as needed to bring the level to the upper mark on the dipstick Dispose of used filter and oil properly 97 MAINTENANCE Transmission Oil Always check and change the transmission oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 85 Maintain the oil level at the bottom of the fill plug hole threads We recommend the use of Polaris Premium AGL Synthetic Gearcase Lubricant See page 143 for the part numbers of Polaris products The fill plug is located on the left side of the ATV under the rear fender behind the wheel The drain plug is located on the right side of the gearcase on the right side of the ATV behind the wheel well Transmission Oil Level 1 Position the vehicle on a level surface Remove the fill plug 3 Check the oil level Add the recommended oil as needed 4 Reinstall the fill plug Torque to 20 25 ft Ibs 27 34 Nm 98 MAINTENANCE Transmission Oil Transmission Oil Change 1 Remove the fill plug 2 Place a drain pan under the gearcase 3 Remove the drain plug Allow the oil to drain completely 4 Clean and reinstall the drain plug Torque to 20 25 ft Ibs 27 34 Nm 5 Add 32 oz 948 ml of the recommended oil 6 Reinstall the fill plug Torque to 20 25 ft Ibs 27 34 Nm 7 Check for leaks Dispose of used oil properly Front Gearcase Demand Drive Fluid Always check and change the demand drive fluid at the intervals out
24. check for obstacles or people behind the ATV When it s safe to proceed back slowly 34 SAFETY Rider Safety A WARNING POTENTIAL HAZARD EE Operating this ATV with improper tires or with improper or uneven tire cmm pressure zm S WHAT CAN HAPPEN Use of improper tires or operation of the ATV with improper or uneven tire pressure could cause loss of control or accident HOW TO AVOID THE HAZARD Always use the size and type of tires specified for the ATV in the owner s manual Always maintain proper tire pressure as described in the owner s manual and on safety decals A WARNING POTENTIAL HAZARD Operating the ATV with improper modifications WHAT CAN HAPPEN Improper installation of accessories or modification of the ATV may cause changes in handling which could lead to an accident HOW TO AVOID THE HAZARD Never modify the ATV through improper installation or use of accessories All parts and accessories added to the vehicle must be genuine Polaris Industries Inc or equivalent components designed for use on this ATV and should be installed and used according to approved instructions See your authorized Polaris ATV dealer for more information 35 SAFETY Rider Safety A WARNING POTENTIAL HAZARD Overloading the ATV or carrying towing cargo improperly WHAT CAN HAPPEN Overloading and towing can cause changes in vehicle handling which could lead to lo
25. 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 No verification of registration will be sent to the purchaser as the copy of the Warranty Registration Form will be the warranty entitle ment If you have not signed the original registration and received the customer copy please contact your dealer immediately NO WARRANTY COVERAGE WILL BE ALLOWED UNLESS YOUR ATV IS REGISTERED WITH POLARIS Initial dealer preparation and set up of your ATV is very important in ensuring trouble free operation Purchasing a machine in the crate or without proper dealer set up will void your warranty coverage 150 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 ATV 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 dam
26. decals on the ATV If any decal becomes illegible or comes off contact your Polaris dealer to purchase a replacement Replacement safety decals are provided by Polaris at no charge The part number is printed on the decal Discretionary Warning WARNING Never operate this ATV on HILLS steeper than 15 degrees 15 To prevent flip over on hilly terrain when going up or down use throttle and brakes gradually Age 16 Warning Never operate this vehicle in lt gt mode on irregular terrain including hills and obstacles REVERSE operation can be dangerous even at low speeds Steering becomes difficult To prevent flipover avoid sudden braking or sharp turns Discretionary Warning Use OVERRIDE for reverse speed limiter with caution To prevent loss of control never activate override button with open throttle When this vehicle is not in operation or unattended place shift in the park position 7175108 Age 16 Warning WARNING Operating this ATV if you are under the age of 16 increases your chance of severe injury or death NEVER operate this ATV if you are under age 16 7172588 SAFETY Safety Decals and Locations General Warning WARNING Improper ATV use can result in SEVERE INJURY or DEATH ALWAYS USE AN APPROVED HELMET AND PROTECTIVE GEAR FOR OPERATOR AND PASSENGER NEVER USE ON PUBLIC ROADS NEVER CARRY MORE THAN ONE PASSENGER NEVER USE WITH DRUGS OR ALCOHOL NEVER operate
27. engine and drive components will result in more efficient performance and longer life for these components CAUTION Excessive heat build up during the first three hours of operation will damage close fitted engine parts and drive components Do not operate at full throttle or high speeds during the first three hours of use Engine and Drivetrain Break in 1 Fill the fuel tank with gasoline See page 45 2 Check the engine oil level on the dipstick See page 90 Add oil if necessary to maintain the level between the safe and add marks 3 Drive slowly at first Select an open area that allows room to famil iarize yourself with vehicle operation and handling 4 Vary the throttle positions Do not operate at sustained idle 5 Perform regular checks on fluid levels controls and areas outlined on the daily pre ride inspection checklist See page 62 6 Pull only light loads 7 During the break in period change both the oil and the filter at 20 hours or one month PVT Break in Clutches Belt A proper break in of the clutches and drive belt will ensure a longer life and better performance Break in the clutches and belt by operating at slower speeds during the break in period as recommended Pull only light loads Avoid aggressive acceleration and high speed operation dur ing the break in period 61 OPERATION Pre Ride Checklist A WARNING If a proper inspection is not done before each use sev
28. for cleaning not recommended exercise extreme caution The water may damage components and could remove paint and decals Avoid directing the water stream at the follow ing items Wheel bearings Radiator Transmission seals Brakes Cab and body panels Labels and decals Electrical components and wiring NOTE If warning and safety labels are damaged contact your Polaris dealer for free replacement Grease all zerk fittings immediately after washing Allow the engine to run for a while to evaporate any water that may have entered the engine or exhaust system Polishing the Vehicle Polaris recommends the use of common household aerosol furniture polish for polishing the finish on your Polaris vehicle Follow the instructions on the container Polishing Tips Avoid the use of automotive products some of which can scratch the finish of your vehicle Always use clean cloths and pads for cleaning and polishing Old or reused cloths and pads may contain dirt particles that will scratch the finish 130 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 NOTE Chrome wheels exposed to road salt or salt in the air in coastal areas are more susceptible to corrosion if not properly cleaned Clean chrome wheels more often if they re exposed to salt or other cor
29. hauling or towing heavy cargo to extend belt life 1 Always load the cargo box with the load as far forward as possible 2 Always operate the vehicle with extreme caution whenever hauling or towing loads Balance handling and control may be affected 3 Slow down 4 Make sure the cargo box dump latch is securely latched before load ing and operating Unintentional dumping will result if weight is placed in the rear of the box and the latch is not secured 65 OPERATION Hauling Cargo Towing Loads Always attach a towed load to the hitch point If towing a load reduce rear box cargo weight by the amount of tongue weight The combination of rear box cargo weight and tongue weight must not exceed the rear box capacity CAUTION Using an improper hitch or exceeding Maximum the maximum tongue weight capacity 6 3 4 17 cm can result in serious damage to the vehicle and will void your ATV warranty Never install a hitch longer than 6 3 4 17 cm Never install automotive accessories on your Polaris ATV Always install Polaris approved or equivalent accessories designed for ATV use Maximum Towing Capacities Do not exceed the following maximum capacities when towing Avoid towing on inclines 500 EFI 700 800 EFI Maximum Towed Load Level Ground 1225 Ibs 557 kg 1500 Ibs 680 kg Maximum Vertical Hitch Weight 120 Ibs 55 kg 150 Ibs 68 kg 66 OPERATIO
30. more frequently See page 122 Insufficient warm up at low ambient tempera tures Warm the engine at least 5 minutes With the transmission in neutral advance the throttle to about 1 8 throttle in short bursts 5 to 7 times The belt will become more flex ible and prevent belt burning Slow easy clutch engage ment Use the throttle quickly and effectively Towing pushing at low RPM low ground speed Use low range only Utility use plowing Use low range only Stuck in mud or snow Shift the transmission to low range and carefully use fast aggressive throttle application to engage clutch WARNING Excessive throttle may cause loss of control and vehicle overturn Climbing over large objects from a stopped position Shift the transmission to low range and carefully use fast brief aggressive throttle application to engage clutch WARNING Excessive throttle may cause loss of control and vehicle overturn Belt slippage from water or snow ingestion into the PVT system Dry out the PVT See page 122 Inspect clutch seals for damage if repeated leaking occurs Clutch malfunction See your Polaris dealer Poor engine performance Check for fouled plugs or foreign material in gas tank or fuel lines See your dealer Slippage from failure to warm up belt Always warm up the belt by operating below 30 mph for one mile 5 miles or more when temperature is below freezing
31. of the cylinder head and appear to be an oil leak Reinstall the spark plug Torque to specification Apply dielectric grease to the inside of each spark plug cap and rein stall the caps onto the plugs Turn the engine over several times Oil will be forced in and around the piston rings and ring lands coating the cylinder with a protec tive film of fresh oil If Polaris fuel system additive is not used the fuel tank fuel lines and injectors should be completely drained of gasoline 133 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 85 Battery Storage See pages 126 127 for storage and charging procedures Storage Area Covers Set the tire pressure and safely support the ATV with the tires slightly off the ground Be sure the storage area is well ventilated Cover the vehicle with a genuine Polaris cover NOTE Do not use plastic or coated materials They do not allow enough ven tilation to prevent condensation and may promote corrosion and oxi dation 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 ATV Always install accessories that are approved for ATV use Please see your Polaris dealer 134 MAINT
32. side of the vehicle to obtain the recommended 1 8 to 1 4 3 6 mm toe out alignment 5 Repeat the measurement procedure on the other side of the vehicle NOTE If you discover improper alignment see your Polaris dealer for service 105 MAINTENANCE Steering Assembly The steering assembly of the ATV should be checked periodically for loose nuts and bolts If loose nuts and bolts are found see your Polaris dealer for service before operating the vehicle Side Panel Removal l 2 Remove the seat Grasp the rear of the side panel near the rear cab With a firm motion pull the panel outward to disengage the side panel from the grommet Pull the panel downward and rearward to remove it When reinstalling side panels align the fasteners and press firmly to secure them Footwell Removal l 2 106 Remove the six screws on the bottom of the footwell Use a flat screwdriver or sidecutters to remove the plastic rivets securing the footwell to the fenders Remove the footwell Rivets MAINTENANCE Tires Refer to the specifications section beginning on page 144 for recom mended tire type size and pressure A WARNING Operating your ATV with worn tires improperly inflated tires non standard tires or improperly installed tires will affect vehicle handling and could cause an accident resulting in serious injury or death Maintain proper tire pressure as described on the decal on your ATV a
33. their meanings before reading the manual A The safety alert symbol on your vehicle or in this manual alerts you to the potential for injury A WARNING The safety alert warning indicates a potential hazard that may result in serious injury or death A CAUTION The safety alert caution indicates a potential hazard that may result in minor injury or damage to the vehicle CAUTION A caution indicates a situation that may result in damage to the vehicle NOTE A note will alert you to important information or instructions 16 SAFETY Rider Safety A WARNING Serious injury or death can result if you do not follow these instructions and procedures which are outlined in further detail within your owner s manual Read this manual and all labels carefully and follow the operating procedures described Never operate an ATV without proper instruction Take a training course Purchasers of a new Polaris ATV and their eligible family members are entitled to take the ATV RiderCourse Contact ATV Enrollment Express at 800 887 2887 or visit www atvsafety org for information on enrollment in the ATV RiderCourses Never allow anyone under 16 years of age to operate this ATV Never allow anyone under 12 years of age to ride as a passenger on this 2 up ATV Make sure any passenger is tall enough to comfortably and safely reach the handgrips and footrests Never secure a passenger to the vehicle or to the
34. to contact the lens Immediately clean off any gasoline that splashes on the instrument cluster 52 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 NOTE Ifthe instrument cluster fails to illuminate a battery over voltage may have occurred and the instrument cluster may have shut off to protect the electronic speedometer If this occurs take the ATV to your Polaris dealer for proper diagnosis 1 Gear Indicator This 3 4 indicator displays gear shifter position H High Gear L Low Gear N Neutral R Reverse Gear P Park 2 4X4 Indicator This indicator illuminates when the 4X4 switch is on either ADC 4X4 or 4X4 3 Engine Hour Display Indicator 4 Service Interval Diagnostic Mode Indicator 5 Low Battery and Over Voltage This warning usually indicates that the ATV is operating at an RPM too low to keep the battery charged It may also occur when the engine is at idle and high elec trical load lights cooling fan accessories is applied Drive at a higher RPM or recharge the battery to clear the warning 6 Odometer Tachometer Tripmeter Hour Meter Clock 7 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 di
35. will also be displayed on the label 12 SAFETY Safe Riding Gear Eye Protection Do not depend on eyeglasses or sunglasses for eye protection When ever riding a Polaris vehicle always wear shatterproof goggles or use a shatterproof helmet face shield Polaris recommends wearing approved Personal Protective Equipment PPE bearing markings such as VESC 8 V 8 Z87 1 or CE Make sure protective eye wear is kept clean Gloves Off road style gloves with knuckle pads are the best for comfort and protection Boots The best footwear 1s 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 13 SAFETY Rider Safety A WARNING Failure to follow the warnings contained in this manual can result in severe injury or death A Polaris ATV is not a toy and can be hazardous to operate This vehicle handles differently than other vehicles such as motorcycles and cars A collision or rollover can occur quickly even during routine maneuvers like turning or driving on hills or over obstacles if you fail to take proper precautions Read and understand your owner s manual and all warnings before operating a Polaris ATV Age Restrictions This vehicle is an ADULT VEHICLE ONLY Operation is prohibited for anyone under 16 years of age Never allow anyone under
36. with the brake lever until the vehicle 1s on more level ground 77 OPERATION Driving Through Water Your ATV can operate through water with a maximum recommended depth equal to the bottom of the footrests Follow these procedures when operating through water 1 Determine water depths and current before crossing 2 Choosea crossing where both banks have gradual inclines 3 Proceed slowly avoiding rocks and obstacles 4 After crossing dry the brakes by applying light pressure to the lever until braking action 1s normal 78 OPERATION Driving Through Water After running the vehicle in water it s critical to have it serviced as out lined in the maintenance chart See page 85 The following areas need special attention engine oil transmission oil demand drive fluid and all grease fittings CAUTION Major engine damage can result if the vehicle is not thoroughly inspected after operation in water Perform the services outlined in the maintenance chart If your vehicle becomes immersed or is operated in water that exceeds the footrest level take it to your dealer for service before starting the engine NOTE Avoid operating the vehicle through deep or fast flowing water If you cannot avoid water that exceeds the recommended maximum depth go slowly balance your weight carefully avoid sudden movements and maintain a slow and steady forward motion Do not make sudden turns or stops and do not ma
37. 11 hours 25 50 0 25 11 5 12 0 volts 11 5 volts or less Needs charge Needs charge with desulfating charger At least 13 hours verify state of charge At least 20 hours 128 MAINTENANCE Cleaning and Storage Washing the Vehicle Keeping your Polaris vehicle clean will not only improve its appearance but it can also extend the life of various components CAUTION High water pressure may damage components Polaris recommends washing the vehicle by hand or with a garden hose using mild soap Certain products including insect repellents and chemicals will damage plastic surfaces Do not allow these types of products to contact the vehicle The best and safest way to clean your Polaris vehicle is with a garden hose and a pail of mild soap and water 1 Usea professional type washing cloth cleaning the upper body first and the lower parts last 2 Rinse with clean water frequently 3 Dry surfaces with a chamois to prevent water spots Washing Tips Avoid the use of harsh cleaners which can scratch the finish Do not use a power washer to clean the vehicle Do not use medium to heavy duty compounds on the finish Always use clean cloths and pads for cleaning and polishing Old or reused cloths and pads may contain dirt particles that will scratch the finish 129 MAINTENANCE Cleaning and Storage Washing the Vehicle If a high pressure water system is used
38. 157 PN 3234451 PN 3234356 1800 3700 10 RH Blue Green Yellow EBS 6000 12000 PN 5630709 PN 7041157 PN 3234451 PN 3234356 NOTE EBS models require no helix spring adjustment 145 SPECIFICATIONS Sportsman X2 700 EFI Maximum Weight Capacity 705 lbs 320 kg includes operator passenger cargo accessories Dry Weight 830 Ibs 376 5 kg base model Front Rack Storage Box Capacity 90 Ibs 41 kg Rear Storage Box Capacity 400 Ibs 181 kg Receiver Hitch Tongue Capacity 150 Ibs 68 kg Rear box capacity and tongue weight not to exceed 400 Ibs 181 kg Receiver Hitch Towing Capacity 1500 Ibs 680 kg on level ground Overall Length 93 in 236 cm Overall Width 48 in 122 cm Overall Height 48 in 122 cm Wheelbase 57 in 145 cm Ground Clearance 11 in 28 cm Minimum Turning Radius 82 in 208 cm unloaded Fuel Capacity 6 gal 22 7 1 Engine Oil Capacity 2 qts 1 9 1 Coolant Capacity 3 4 qts 3 2 1 Demand Drive Fluid Capacity 9 3 oz 275 ml Transmission Oil Capacity 32 oz 948 ml Engine EHO0680LE Displacement 683 cc Bore x Stroke 80 x 68 Alternator Output 500 Watts 223000 RPM Compression Ratio 9 40 1 Starting System Electric Fuel System Electronic Fuel Injection Ignition System ECU Ignition Timing 8 BTDC 2000 RPM Spark Plug RC7YC Spark Plug Gap 035 in 0 9 mm Lubr
39. 5290 Canada 1 204 925 7100 154 WARRANTY U S A EPA Emissions Limited Warranty This AII Terrain Vehicle ATV or Off Road Utility Vehicle ORUV emissions limited warranty is in addition to the Polaris standard limited warranty for this vehicle Polaris warrants that this vehicle is 1 designed built and equipped to conform at the time of initial sale with the requirements of 40 CFR 1051 and 2 free from defects in materials and workmanship that may keep it from meeting these requirements The emissions warranty period for this vehicle begins on the date the vehicle is deliv ered to the original retail purchaser and ends 30 months 2 5 years after that date after 5000 km 3100 miles or after 500 hours of operation whichever comes first This emission related warranty covers components whose failure would increase an engine s emissions including electronic controls fuel injection exhaust gas recircula tion aftertreatment or any other system utilized in this vehicle to control emissions Replacing or repairing other components not covered by this emissions warranty or the standard warranty is the responsibility of the owner including the parts labor and other costs associated with recommended maintenance The exclusive remedy for breach of this limited warranty shall be at the exclusive option of Polaris repair or replacement of any defective materials components or prod ucts THE REMEDIES SET FORTH IN THIS LIMITED WA
40. Always use 2W 50 oil Follow the manufacturer s recommendations for ambient tempera ture operation See page 143 for the part numbers of Polaris products CAUTION Mixing brands or using a non recommended oil may cause serious engine damage Always use the recommended oil Never substitute or mix oil brands 90 MAINTENANCE Engine Oil Oil Level 500 EFI Access the oil dipstick and fill tube from the left side of the ATV NOTE A rising oil level between checks in cool weather driving can indicate contaminants such as gas or moisture col lecting in the crankcase If the oil level is over the full safe mark change the oil immedi Que ately Dipstick X 1 Position the vehicle on a level surface 2 Startthe engine Allow itto idle Safe Range for 20 30 seconds Stop the MESA engine f 3 Remove the dipstick Wipe it dry with a clean cloth 4 Reinstall the dipstick Add Oil Safe completely 5 Remove the dipstick and check the oil level Maintain the oil level in the safe range Do not overfill 6 Reinstall the dipstick securely 91 MAINTENANCE Engine Oil Oil Level 700 800 EFI Access the oil dipstick and fill tube from the left side of the ATV 1 Position the vehicle on a level surface 2 Liftthe lever lock to remove the dipstick Wipe it dry with a clean cloth 3 Reinstall the dipstick com pletely but do not lock it NOTE The dipstick must be inserted comp
41. D Technician Your Polaris dealer knows your vehicle best and is interested in your total satisfaction Be sure to return to your dealership for all of your ser vice needs during and after the warranty period We also take great pride in our complete line of apparel parts and acces sories available through our online store at www purepolaris com Have your accessories and clothing delivered right to your door POLARIS The Way Out POLARIS and POLARIS THE WAY OUT are registered trademarks of Polaris Indus tries Inc Copyright 2007 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 2008 Sportsman 500 700 800 X2 Owner s Manual P N 9921356 2 TABLE OF CONTENTS Know Your Vehicle 5 Safety 44 40 erence Sse ee eemast rre 6 Features and Controls 38 Operation soc se dwt Oe ees 60 Emission Control Systems
42. ENANCE Transporting the ATV Follow these procedures when transporting the vehicle 1 Stop the engine 2 Place the transmission in PARK 3 Lock the parking brake 4 Always secure the seat in the 1 up position to prevent loss during transporting 5 Secure the fuel cap and oil cap 6 Always tie the frame of the ATV to the transporting unit securely with suitable straps or rope Do not attach tie straps to the front A arm bolt pockets 7 Remove the key to prevent loss during transporting 135 ADJUSTMENTS Camber and Caster The camber and caster are non adjust able Rear Spring The rear shock absorber spring is adjusted by rotating the adjuster either clockwise or counterclockwise to increase or decrease spring tension NOTE Accessory springs are available through your Polaris dealer 136 Adjuster ADJUSTMENTS Handlebars The handlebars can be adjusted for rider preference A WARNING Improper adjustment of the handlebars or incorrect torquing of the adjuster block tightening bolts can cause limited steering or loosening of the handlebars resulting in loss of control and possible serious personal injury or Sagat Follow the adjustment procedures exactly or see your Polaris dealer or service 1 Remove the upper headlight pod 2 Loosen the four handlebar bolts 3 Adjust the handlebar to the desired height NOTE Be sure the handlebars do not contact the gas
43. N Hauling Cargo Dumping Cargo 1 Select a level site to dump the cargo box Do not attempt to dump or unload the vehicle while parked on an incline Place the transmission in PARK Lock the parking brake Dismount the vehicle Um Wm oA D Lower the tailgate A WARNING If cargo weight is placed toward the rear of the cargo box the load may dump unexpectedly and cause serious injury When loading cargo always position the weight as far forward and as low as possible 6 Pullthe cargo box release lever upward 7 Liftthe front of the cargo box and dump the cargo Dump Box 8 Lower the cargo box and make EU n sure the release latch is Latch secured 9 Secure the tailgate A WARNING Operating with the cargo box in the raised position can cause serious injury and damage to the vehicle The cargo box could close unexpectedly and injure the driver The rear tires will also catch the rear of the bed damaging the vehicle and creating hazardous driving conditions Never operate this vehicle with the cargo box in the raised position 67 OPERATION Driving Procedures Cy Uh de coa b em 8 9 10 11 Wear protective riding gear See page 12 Perform the pre ride inspection See page 62 Place the transmission in PARK Lock the parking brake Mount the vehicle from the left side Sit upright with both feet on the footrests and both hands on the handlebars Start the e
44. PEN Severe injury and or death could occur if a child under the minimum age recommendation operates this ATV or rides as a passenger Even though a child may be within the recommended age group for operating some ATVs he she may not have the skills abilities or judgment needed to operate or ride on this ATV safely and could be susceptible to accident or injury HOW TO AVOID THE HAZARD No one under the age of 16 should operate a Polaris ATV Never allow anyone under 12 years of age to ride as a passenger on this 2 up ATV 22 SAFETY Rider Safety A WARNING POTENTIAL HAZARD Operating with more than one passenger WHAT CAN HAPPEN Passengers affect balance and steering and increase the risk of losing control which can result in severe injury or death HOW TO AVOID THE HAZARD Never operate the 2 up ATV with more than one passenger A WARNING POTENTIAL HAZARD Carrying a passenger in the cargo box WHAT CAN HAPPEN A passenger riding in the cargo box could fall from the vehicle unexpectedly or may contact moving components both of which can result in severe injury or death HOW TO AVOID THE HAZARD Never allow a passenger to ride in the cargo box A WARNING POTENTIAL HAZARD Operating an ATV on paved surfaces including sidewalks paths parking lots and driveways WHAT CAN HAPPEN ATV tires are designed for off road use Operating on paved surfaces may adversely affec
45. RRANTY ARE THE ONLY REMEDIES AVAILABLE TO ANY PERSON FOR BREACH OF THIS WAR RANTY POLARIS SHALL HAVE NO LIABILITY TO ANY PERSON FOR INCI DENTAL CONSEQUENTIAL OR SPECIAL DAMAGES OF ANY DESCRIPTION WHETHER ARISING OUT OF EXPRESS OR IMPLIED WAR RANTY OR ANY OTHER CONTRACT NEGLIGENCE OR OTHER TORT OR OTHERWISE ALL IMPLIED WARRANTIES INCLUDING BUT NOT LIMITED TO ANY IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PAR TICULAR PURPOSE ARE LIMITED IN DURATION TO THE WARRANTY PERIOD DESCRIBED HEREIN POLARIS DISCLAIMS ALL EXPRESS WARRAN TIES NOT STATED IN THIS WARRANTY Some states do not allow limitations on how long an implied warranty lasts so the above limitation may not apply if it is incon sistent with the controlling state law This limited warranty excludes failures not caused by a defect in material or workman ship This limited warranty does not cover damage due to accidents abuse or improper handling maintenance or use This limited warranty also does not cover any engine that has been structurally altered or any engine that has been used in racing competition This limited warranty also does not cover physical damage corrosion or defects caused by fire explosions or other similar causes beyond the control of Polaris If you have any questions regarding your warranty rights and responsibilities you should contact the Polaris Warranty Department at 1 888 704 5290 155 MAINTENANCE LOG Present this section of you
46. RUN OFF switch is off lt gt NOTE Both the main switch and the engine stop switch will shut off all electri cal power to the vehicle including lights Main Key Switch Use the main key switch to start the engine See page 63 4X4 Switch Use the 4X4 switch to engage ADC 4X4 4X4 or 2X4 See page 49 38 FEATURES AND CONTROLS Switches Differential Switch Use the differential switch to lock and unlock the rear differential Locked Differential Operate the vehicle with the switch in e the locked position in most conditions inside wheel will rotate independently from the outside wheel during turns Operate with an unlocked differential only as needed to protect smooth level surfaces from tire damage Otherwise move the switch to the locked position 7his feature will function only if the vehicle is in 2X4 mode A WARNING 4 Unlocked Differential When the differential is unlocked the Operating with the differential unlocked lt 3 when on sloped uneven or loose terrain could cause loss of control and result in serious injury or death One rear wheel may slip and lose traction or may lift up and grab when it touches the ground again DO NOT operate with the differential unlocked lt 3 when climbing or descending hills when sidehilling or when operating on uneven loose or slippery terrain such as sand gravel ice snow obstacles and water crossings Place the differential switch in the locked posi
47. S 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 HOW TO OBTAIN WARRANTY SERVICE If your ATV requires warranty service you must take it to a Polaris dealer authorized to repair Polaris ATVs 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 person at Polaris This warranty gives you specific legal rights and you may also have other rights which vary from state to state If any of the above terms are void because of state or federal law all other warranty terms will remain in effect Engine Oil 1 Mixing oil brands or using non recommended oil may cause engine damage We rec ommend the use of Polaris engine oil for your ATV 2 Damage resulting from the use of non recommended lubricants may not be covered by warranty SPARK ARRESTOR Polaris warrants that the spark arrestor in this vehicle will meet the efficiency require ments of 43 CFR 8340 1 c
48. TE The filter is effective with the arrow pointing in either direction CAUTION Operation of your vehicle without a breather filter can cause engine damage Always reinstall the breather filter after removing it for service 110 MAINTENANCE Fuse Replacement If the engine stops or will not start or if you experience other electrical failures a fuse may need replace ment NOTE Spare fuses are provided in a compartment on the top of the access door 1 Open the front box cover and pull open the access door 2 Remove the suspect fuse from the fuse panel If the fuse is blown install a new fuse with the same amperage 3 Secure the access door 4 Secure the box cover 111 MAINTENANCE Lights When servicing a halogen lamp don t touch the lamp with bare fingers Oil from your skin leaves a residue causing a hot spot that will shorten the life of the lamp A WARNING Poor lighting while driving can result in severe injury or death Headlight and taillight lenses become dirty during normal operation Wash the headlights frequently to maintain lighting quality Hot components can cause serious burns to skin Allow lamps to cool before servicing Headlight Lamp Replacement 1 Remove the two screws on the lower front corners of the headlight pod Remove the screw from the rear of the pod 3 Lift the pod slightly while depressing the tabs at the rear of the pod Lift the po
49. TFE seal tape 10 Reinstall the screen fitting and rotate the fitting clockwise a mini mum of 2 1 2 turns into the tank threads Continue to rotate the fit ting until the nipple of the fitting aligns with the mark on the tank NOTE Do not over tighten Maximum torque for the screen fitting is 25 ft Ibs 34 Nm 11 Reattach the oil line 93 MAINTENANCE Engine Oil Cil and Filter Change 500 EFI 12 Place shop towels beneath the oil filter Using an oil filter wrench turn the filter counterclockwise to remove it 13 Make sure the o ring from the old filter is completely removed from the engine Using a clean dry cloth clean the filter sealing sur face on the crankcase 14 Lubricate the o ring on the new filter with a film of fresh engine oil Check to make sure the o ring is in good condition 15 Install the new filter and rotate it clockwise by hand until the filter gasket contacts the sealing surface then turn it an additional 1 2 turn 16 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 NOTE The sealing surfaces on the drain plug and crankcase should be clean and free of burrs nicks or scratches 17 Reinstall the drain plug Torque to 14 ft Ibs 19 Nm 18 Remove the dipstick 19 Add two quarts 1 9 1 of recommended oil Reinstall the dipstick NOTE If the sump is not drained add about 1 3 4 quarts
50. URES AND CONTROLS Instrument Cluster Rider Information Center Diagnostic Mode The wrench icon will display when the gauge is in the diagnostic mode To exit the diagnostic mode turn the key switch off and on Any move ment of the tires will also cause the gauge to exit the diagnostic mode To enter the diagnostics mode 1 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 4 5 6 7 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 NOTE Do not turn the key switch off until the display stops flashing or the new setting will not be locked into the memory 55 FEATURES AND CONTROLS Instrument Cluster Rider Information Center Diagnostic Mode Battery Voltage Screen View this sc
51. ages 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 ATV 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 ATV The exclusive remedy for breach of this warranty shall be at Polaris exclusive option repair or replacement of any defective materials or com ponents or products THE REMEDIES SET FORTH IN THIS WARRANTY ARE THE ONLY REMEDIES AVAILABLE TO ANY PERSON FOR BREACH OF THIS WAR RANTY POLARIS SHALL HAVE NO LIABILITY TO ANY PERSON FOR INCI DENTAL CONSEQUENTIAL OR SPECIAL DAMAGES OF ANY DESCRIPTION WHETHER ARISING OUT OF EXPRESS OR IMPLIED WARRANTY OR ANY OTHER CONTRACT NEGLIGENCE OR OTHER TORT OR OTHERWISE 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 151 WARRANTY 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 SIX MONTH WARRANTY PERIOD POLARIS FURTHER DISCLAIM
52. al as the system is purging itself of trapped air Check the coolant level and maintain as recommended by adding coolant to the recovery bottle Polaris recommends the use of Polaris 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 already premixed and ready to use Do not dilute with water See page 143 for the part numbers of Polaris products NOTE Always follow the manufacturer s mixing recommendations for the freeze protection required in your area Recovery Bottle Coolant The recovery bottle is located on the left side of the vehicle 1 Remove the left side panel See page 106 2 Maintain the coolant level between the minimum and maximum marks on the bot tle when the fluid is cool 3 Add coolant as needed K Ne C Recovery Bottle 102 MAINTENANCE Cooling System Radiator Coolant To ensure that the coolant maintains its ability to protect the engine Polaris recommends that you drain the system completely every two years and add a fresh mixture of antifreeze and water Replace the coolant any time the cooling system has been drained for maintenance or repair If the recovery bottle has run dry check the level in the radiator Add coolant as needed A WARNING Escaping steam can cause severe burns Never remove the pressure cap while the engine is warm or hot Always allow the engine
53. argo accessories Dry Weight 880 Ibs 399 kg base model Front Rack Storage Box Capacity 90 Ibs 41 kg Rear Storage Box Capacity 400 Ibs 181 kg Receiver Hitch Tongue Capacity 150 Ibs 68 kg Rear box capacity and tongue weight not to exceed 400 Ibs 181 kg Receiver Hitch Towing Capacity 1500 Ibs 680 kg on level ground Overall Length 93 in 236 cm Overall Width 48 in 122 cm Overall Height 48 in 122 cm Wheelbase 57 in 145 cm Ground Clearance 11 in 28 cm Minimum Turning Radius 82 in 208 cm unloaded Fuel Capacity 6 gal 22 7 1 Engine Oil Capacity 2 qts 1 9 1 Coolant Capacity 3 4 qts 3 2 1 Demand Drive Fluid Capacity 9 3 oz 275 ml Transmission Oil Capacity 32 oz 948 ml Engine EH0760LE Displacement 760 cc Bore x Stroke 80x76 Alternator Output 500 Watts 223000 RPM Compression Ratio 10 1 Fuel System Electronic Fuel Injection Ignition System Electronic Ignition Ignition Timing Variable ECU controlled Spark Plug RC7YC Spark Plug Gap 035 in 0 9 mm Lubrication System Pressurized Wet Sump Driving System Type Automatic PVT Polaris Variable Transmission Front Suspension MacPherson strut with 8 2 21 cm travel Rear Suspension Progressive rate with 8 75 22 cm travel 148 SPECIFICATIONS Sportsman X2 800 EFI
54. 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 NOTE 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 58 FEATURES AND CONTROLS Instrument Cluster Rider Information Center Downloading Codes Blink Failure Description Code 12 BEGIN SEQUENCE 22 Throttle Position Sensor Low 22 Throttle
55. cohol or drugs WHAT CAN HAPPEN Consumption of alcohol and or drugs could seriously affect operator judgment Reaction time may be slower and operator balance and perception could be affected Consuming alcohol and or drugs before or while operating an ATV could result in an accident causing severe injury or death HOW TO AVOID THE HAZARD Never consume alcohol or drugs before or while operating an ATV A WARNING POTENTIAL HAZARD Operating the ATV at excessive speeds WHAT CAN HAPPEN Excessive speed increases the operator s chance of losing control of the ATV which can result in an accident causing severe injury or death HOW TO AVOID THE HAZARD Never operate at excessive speeds Travel at speeds appropriate for your skills your passenger s skills and operating conditions 25 SAFETY Rider Safety A WARNING POTENTIAL HAZARD Attempting jumps and other stunts WHAT CAN HAPPEN Attempting stunts increases the chance of an accident including an overturn HOW TO AVOID THE HAZARD Never attempt jumps or other stunts Avoid exhibition driving A WARNING POTENTIAL HAZARD Failure to inspect the ATV before operating Failure to properly maintain the ATV WHAT CAN HAPPEN Poor maintenance increases the possibility of an accident or equipment damage HOW TO AVOID THE HAZARD Always inspect your ATV before each use to make sure it s in safe operating condition Alwa
56. condition Always follow the inspection and maintenance procedures and schedules outlined in your owner s manual Always travel slowly and use extra caution when operating on unfa miliar terrain Be alert to changing terrain conditions Never operate on excessively rough slippery or loose terrain Always follow proper turning procedures as described in this manual Practice turning at low speeds before attempting to turn at faster speeds Do not turn at excessive speeds Always have the ATV inspected by an authorized Polaris dealer if it s been involved in an accident Never operate on hills too steep for the ATV or for your abilities Practice on smaller hills before attempting larger hills Never operate with the differential unlocked 4 while operating on a hill or other irregular terrain See pages 39 and 49 Always follow proper procedures for climbing hills Check the terrain carefully before ascending a hill Never climb hills with excessively slippery or loose surfaces Shift your weight uphill Never open the throttle suddenly or make sudden gear changes Never go over the top of a hill at high speed Always move the 4X4 switch to ADC 4X4 before ascending or descending a hill SAFETY Rider Safety Always follow proper procedures for going downhill and for braking on hills Check the terrain carefully before you start down a hill Shift your weight uphill Never go down a hill at high speed Avoid going down a hill at a
57. ctly downhill Shift body weight uphill Dr Rw Apply the brakes slightly to aid in slowing NOTE Before operating your ATV learn how to use the auxiliary brake for emergency situations if single lever brakes become inoperable 75 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 76 OPERATION Turning Around on a Hill K Turn l 2 3 7 Stop and lock the parking brake while keeping body weight uphill Always move the 4X4 switch to ADC 4X4 before ascending or descending a hill See page 49 Leave the transmission in forward and shut off the engine If a passenger is on board ask the passenger to dismount first then the operator may dismount Dismount on the uphill side of the vehi cle or on the left if the vehicle is pointing straight uphill Staying uphill of the vehicle turn the handlebars full left While holding the brake lever release the parking brake lock and slowly allow the vehicle to roll around to your right until it s point ing across the hill or slightly downward Lock the parking brake Remount the vehicle from the uphill side keeping body weight uphill NOTE A passenger should not remount until the vehicle returns to firm level 8 9 ground Start the engine with the transmission still in forward Release the parking brake and proceed s owly controlling speed
58. d Do not modify engine or clutch Doing so can cause part failure possible imbalance and excessive engine RPM which can result in serious injury or death 7172563 10 SAFETY Safety Decals and Locations Reverse Override Warning 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 7175106 Box Warning WARNING Remove flammable material NS containers from box before filling Gt A WARNING Passengers can be thrown off This can cause serious injury or death Never carry passengers in cargo box Maximum Box Load 400 Ibs 181 kg 7173890 11 SAFETY Safe Riding Gear Always wear appropriate clothing when riding an ATV Wear protective clothing for comfort and to reduce the chance of injury Helmet Eye Protection Gloves Helmet Wearing a helmet can prevent a severe head injury Whenever riding a Polaris vehicle always wear a helmet that meets or exceeds established safety standards Approved helmets in the USA and Canada bear a U S Department of Transportation DOT label 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 0006 31 number
59. d can cause loss of consciousness resulting in severe injury or death Never run an engine in an enclosed area 1 Position the vehicle on a level surface 2 Place the transmission in PARK 3 Lock the parking brake NOTE The starter interlock will prevent the engine from starting if the trans mission is in gear and the brake is not engaged 4 Sitonthe vehicle and move the engine stop switch to RUN NOTE Do not press the throttle while starting the engine 5 Turn the ignition key past the ON position to engage the starter Activate the starter for a maximum of five seconds releasing the key when the engine starts 500 EFI ONLY The starter will automatically stop if engaged for longer than 5 seconds Move the key to the OFF position and wait 10 seconds before engaging the starter again 6 Ifthe engine does not start return the key to the OFF position and wait five seconds before attempting to start again Activate the starter for another five seconds if necessary Repeat this procedure until the engine starts CAUTION Operating the vehicle immediately after starting could cause engine damage Allow the engine to warm up for several minutes before operating the vehicle Cold Weather Operation If the ATV is used year round check the oil level frequently A rising oil level could indicate the accumulation of contaminates such as water or excess fuel in the bottom of the crankcase Water in the botto
60. d cover and disconnect the speedometer harnesses from the speedometer 5 Unplug the headlamp from the wiring harness Be sure to pull on the connector not on the wiring 6 Turn the lamp counterclockwise to remove it 7 Apply dielectric grease to the socket and install the new lamp NOTE Make sure the tab on the lamp locates properly in the housing 8 Reassemble the pod 112 MAINTENANCE Lights High Beam Adjustment The headlight beam can be adjusted slightly upward or downward Use the following procedure to make the adjustment 25 ft 7 6 m Position the vehicle on a level surface with the headlight approxi mately 25 ft 7 6 m from a wall Place the transmission in PARK Measure the distance from the floor to the center of the headlight and make a mark on the wall at the same height Start the engine Turn the headlight switch to high beam Observe the headlight aim on the wall The most intense part of the headlight beam should be two inches 5 cm below the mark on the wall NOTE Include rider weight on the seat when measuring 5 The adjustment knob is located on the right side of the headlight pod Adjust the beam to the desired position by turning the knob either clockwise or counterclockwise Low Beam Adjustment Phillips Screw The low beam can be adjusted slightly upward or downward 1 2 Loosen the phillips screw located at the rear of the headlamp Tilt the headlamp u
61. e rack or cargo bed Stability and maneuverability may be adversely affected causing the machine to overturn BALANCE LOADS proportionally between the front rack and cargo bed but do not exceed the stated load capacity Carrying a load on only the front rack or cargo bed may cause an imbalanced condition and increases the possibility of vehicle overturn USE EXTREME CAUTION when applying brakes with a loaded vehicle Avoid terrain or situations that may require backing downhill Always attach the tow load to the hitch point DO NOT TRAVEL FASTER THAN THE RECOMMENDED SPEEDS The vehicle should never exceed 10 mph 16 kph while towing a load on a level surface Vehicle speed should never exceed 5 mph 8 kph when towing loads in rough terrain while cornering or while ascending or descending a hill DO NOT BLOCK THE FRONT HEADLIGHT BEAM when carrying loads on the front rack 64 Hauling Cargo Your ATV has been designed to carry or tow a certain amount of load Always read and understand the load distribution warn ing labels on the vehicle and never exceed the weight capacities outlined in the specifications section of the owner s manual and on the safety decals Cargo weight should be mounted as low as possible When operating over rough or hilly terrain reduce speed OPERATION and cargo weight to maintain stable driving conditions Do not obstruct the headlight beam with cargo Use low forward gear when
62. e in the Maintenance Log beginning on page 156 NOTE Service and adjustments are important for proper vehicle operation If you re not familiar with safe service and adjustment procedures have a qualified dealer perform these operations Maintenance intervals in the following chart are based upon average riding conditions and an average vehicle speed of approximately 10 miles per hour Vehicles subjected to severe use must be inspected and serviced more frequently Severe Use Definition Frequent immersion in mud water or sand Racing or race style high RPM use Prolonged low speed heavy load operation Extended idle Short trip cold weather operation Pay special attention to the oil level A rise in oil 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 85 MAINTENANCE Periodic Maintenance Chart Maintenance Chart Key P Perform these operations more often for vehicles subjected to severe use E Emission related service Failure to conduct this maintenance will not void the emissions warranty but may affect emissions B6 Have an authorized Polaris dealer perform these services A WARNING Improperly performing the procedures marked with a lil could result in component failure and lead to serious inju
63. e special wrench provided in the tool pouch rotate the spark plug counterclockwise to remove it 3 Reverse the procedure for spark plug installation Torque to specifi cation 116 MAINTENANCE Spark Plugs Spark Plug Inspection Normal Spark Plug The normal insulator tip 1s gray tan or light brown There will be few combustion deposits The electrodes are not burned or eroded This indi cates the proper type and heat range for the engine and the service NOTE The tip should not be flaky and white A white insulator tip indicates overheating caused by use of an improper spark plug or incorrect fuel Wet Fouled Spark Plug The wet fouled insulator tip is black A damp oil film covers the firing end There may be a carbon layer over the entire nose Generally the electrodes are not worn General causes of fouling are excessive oil use of non recommended oil or incorrect throttle body adjustments Recoil Housing 500 EFI Always drain the recoil housing after operating the vehicle in wet condi tions Drain the housing before storing the vehicle Make sure the hous ing is completely dry before reinstalling the drain plug 1 Stop the engine 2 Place the transmission in gear 3 Lock the parking brake 4 Remove the drain screw on the bottom of the recoil housing 5 Reinstall the drain screw NOTE Do not open the crankcase drain unless the engine has ingested e water On 4 cycle engines some engine o
64. e sure the passenger is at least 12 years of age and is tall enough to comfortably reach the footrests and grab handles for smaller passengers Please see your Polaris dealer about installing or purchasing a footwell riser kit Make sure the passenger is wearing appropriate riding gear includ ing an approved helmet with a rigid chin guard See page 12 Perform the pre ride inspection See page 62 Convert the seat for 2 up riding See page 50 Make sure the passenger seat lock out is function ing properly Lock the parking brake Mount the vehicle from the left side After the operator is seated the passenger should mount the vehicle from the left side Always make sure the brake is engaged to ensure the vehicle remains motionless whenever a passenger mounts or dismounts Allow a passenger to ride only in the approved passenger seat Do not carry more than one passenger Slow down Control may be more difficult with a passenger on board Allow more time and distance for braking OPERATION Driving with a Passenger 10 11 12 13 14 Ride to the ability of your passenger instead of to your own ability Avoid unexpected or aggressive maneuvers that could cause a pas senger to fall from the vehicle Do not cross a hillside with a passenger on board See page 74 A passenger should always be seated in the passenger seat with both feet on the footrests and both hands on the passenger grab
65. e sure the passenger seat lock out is functioning properly before operating with a passenger Do not operate the vehicle with the seat in the 2 up position when oper ating without a passenger Always return the seat to the 1 up position for single rider operation Never carry cargo in the rear box when operating the ATV in the 2 up mode with a passenger Seat Conversion 1 Make sure the cargo box dump lever is securely latched 2 Rotate both operator backrest latches 1 4 turn to release the locks 3 Tilt the backrest slightly forward 4 Pull the passenger backrest upward from the bed of the cargo box Operator Backrest Latches view from front Locked Unlocked Passenger Dump Lever Backrest 50 FEATURES AND CONTROLS Passenger Seat Seat Conversion 5 Lift the adjustment latch at the top of the passenger backrest Raise the backrest to the desired position Release the latch making sure it locks into one of the three operating positions NOTE The backrest must be moved out of the lowest position before it can be secured in the upright position The lowest position is for seat storage only Do not leave the backrest in the lowest position Always adjust the backrest to one of the three operating positions Lower the operator backrest to create the Backrest Adjustment Latch passenger seat Two retaining pins under the seat should fit into the two grommets on the seat base Test t
66. e the demand drive unit is moving it will not disengage until the rear wheels regain traction Engage the 4X4 switch before getting into conditions where front wheel drive may be needed If the rear wheels are spinning release the throttle before switching to 4X4 CAUTION 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 48 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 a four of the follow ing conditions occur The 4X4 switch must be in the ADC 4X4 position Vehicle speed must be 15 mph 24 km h or less The throttle must be closed throttle lever released The transmission must be in gear high low or reverse Disengaging Active Descent Control The ADC system will automatically disengage if at least one of the fol lowing conditions occur The 4X4 switch is moved out of the ADC 4X4 position Vehicle speed exceeds 15 mph 24 km h The throttle is open throttle is applied The transmission is shifted to neutral or park 49 FEATURES AND CONTROLS Passenger Seat Always mak
67. em for fluid leaks 3 Check the brakes for excessive travel or spongy feel 4 Check the friction pads for wear damage and looseness Replace brake pads when they are worn to 3 64 1 mm 5 Check the security and surface condition 3 64 1 mm of the disc Auxiliary Foot Brake The hydraulic auxiliary brake system requires no adjustment Check the brake fluid level frequently for the auxiliary brake system See page 44 104 Toe Alignment MAINTENANCE A WARNING Severe injury or death can result from improper toe alignment and adjustment Do not attempt to adjust tie rod alignment All tie rod adjustments should be performed by an authorized Polaris dealer Use the following procedure to check the toe alignment of the vehicle The recommended toe alignment is 1 8 to 1 4 3 6 mm toe out 1 Position the vehicle on a level surface Ye 2 Place the handlebars in a Stand S straight ahead position or A 3 Tie a length of string String I ue E between two stands as N shown in the illustration D x Position the stands so nd that the string is flush LUI E with the side of the rear EU J tire NOTE If available you may use a long straight 2 edge instead of string 4 Measure the distance 1 Ei from the string to the rim at the front 1 and O rear 2 of the front rim The rear measurement should be 1 16 1 8 2 3 mm more than the front measurement on each
68. ent line Inspect and replace Low octane fuel Replace with recommended fuel Clogged fuel filter Replace filter Incorrect fuel Possible Rich Fuel Cause Fuel is very high octane Replace with recommended fuel Solution Replace with lower octane fuel Stopping starting without adequate warm up Allow engine to warm up before operat ing and or stopping Incorrect fuel Replace with recommended fuel Clogged air filter Inspect and clean or replace 141 TROUBLESHOOTING Engine Stops or Loses Power Possible Cause Out of fuel Solution Refuel cycle key to ON position three times for 5 seconds each then start Kinked or plugged fuel vent line Inspect and replace Water is present in fuel Replace with new fuel Fouled or defective spark plug s Inspect clean and or replace spark plug s Worn or defective spark plug wires See your dealer Incorrect spark plug gap or heat range Set gap to specs or replace plug Loose ignition connections Check all connections and tighten Low battery voltage Recharge the battery to 12 8 VDC Incorrect fuel Replace with fresh recommended fuel Clogged air filter Inspect and clean or replace Reverse speed limiter malfunction See your dealer Electronic throttle control malfunction Other mechanical failure See your dealer See your dealer Overheated engine
69. er perform these services 88 Lubrication Guide Check and lubricate all components at the intervals outlined in the Periodic Maintenance Chart beginning on page 85 Items not listed in the chart should be lubricated at the General Lubrication interval NOTE MAINTENANCE 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 Item Lube Capacity at Inspection Procedure Fluid Change Engine Oil PS 4 PLUS 2 qt 1 9 I See page 90 Performance Synthetic 2W 50 Brake Fluid DOT 4 Only See page 42 Transmission Oil Polaris AGL Syn 32 oz 948 ml See page 98 thetic Gearcase Lube Demand Drive Demand Drive LT 9 3 oz 275 ml See page 99 Fluid Front Gearcase Premium Fluid ADC Fluid Polaris ADC Fluid See page 100 Front Prop Shaft Yoke Polaris Premium U Joint Lube Grease fittings 3 pumps maximum every 500 miles before long periods of stor age or after pressure wash ing or submerging Front Prop Shaft Yoke 89 MAINTENANCE Engine Oil Oil Recommendations 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
70. ere injury or death could result Always inspect the vehicle before each use to ensure it s in proper operating condition Item Remarks Page Passenger seat lock out Ensure proper operation 50 Brake system lever travel Ensure proper operation 104 Brake fluid Ensure proper level 42 Auxiliary brake Ensure proper operation 44 Front suspension Inspect lubricate if necessary 89 Rear suspension Inspect lubricate if necessary 89 Steering Ensure free operation Tires Inspect condition and pressure 107 Wheels fasteners Inspect ensure fastener tightness 10 Frame nuts bolts fasteners Inspect ensure tightness Fuel and oil Ensure proper levels an Coolant level if applicable Ensure proper level 10s Coolant hoses if applicable Inspect for leaks Throttle Ensure proper operation ane Indicator lights switches Ensure operation 38 Engine stop switch Ensure proper operation 38 Air filter pre filter Inspect clean 109 Air box sediment tube Drain deposits whenever visible Headlamp Check operation apply Polaris dielec 39 tric grease when lamp is replaced 112 Brake light taillight Check operation apply Polaris dielec 115 tric grease when lamp is replaced Riding gear Wear approved helmet goggles and 12 protective clothing ADC Fluid Ensure proper level 100 62 OPERATION Starting the Engine A WARNING Engine exhaust contains poisonous carbon monoxide an
71. errain WHAT CAN HAPPEN Operating on excessively rough slippery or loose terrain could cause loss of traction or loss of control which could result in an accident or overturn HOW TO AVOID THE HAZARD Do not operate on excessively rough slippery or loose terrain until you ve learned and practiced the skills necessary to control the ATV on such terrain Always use extra caution on rough slippery or loose terrain A WARNING POTENTIAL HAZARD Turning improperly WHAT CAN HAPPEN Improper turns could cause loss of control and lead to a collision or overturn HOW TO AVOID THE HAZARD Always follow proper procedures for turning as described in the owner s manual Practice turning at slow speeds before attempting to turn at faster speeds Never turn at excessive speed 28 SAFETY Rider Safety A WARNING POTENTIAL HAZARD Operating on excessively steep hills WHAT CAN HAPPEN The vehicle may overturn HOW TO AVOID THE HAZARD Never operate on hills too steep for the ATV or for your abilities Never operate the ATV on hills steeper than 15 degrees A WARNING POTENTIAL HAZARD Climbing hills improperly WHAT CAN HAPPEN Improper hill climbing could cause loss of control or overturn HOW TO AVOID THE HAZARD Always follow proper procedures for climbing hills as described in the owner s manual See page 73 Always move the 4X4 switch to ADC 4X4 before ascendi
72. for at least 1000 hours when subjected to normal use and when maintenance and installation are in accordance with Polaris recommendations 152 WARRANTY Exported Vehicles EXCEPT WHERE SPECIFICALLY REQUIRED BY LAW THERE IS NO WAR RANTY OR SERVICE BULLETIN COVERAGE ON THIS VEHICLE IF IT IS SOLD OUTSIDE THE COUNTRY OF THE SELLING DEALER S AUTHORIZED LOCA TION This policy does not apply to vehicles that have received authorization for export from Polaris Industries Dealers may not give authorization for export You should consult an authorized dealer to determine this vehicle s warranty or service bulletin coverage if you have any questions This policy does not apply to vehicles registered to government officials or military per sonnel on assignment outside the country of the selling dealer s authorized location This policy does not apply to Safety Recalls How to Get Service In the Country where your vehicle was purchased Warranty or Service Bulletin repairs must be done by an authorized Polaris dealer If you move or are traveling within the country where your vehicle was purchased Warranty or Service Bulletin repairs may be requested from any authorized Polaris dealer who sells the same line as your vehicle Outside the Country where your vehicle was purchased If you are traveling temporarily outside the country where your vehicle was purchased you should take your vehicle to an authorized Polaris dealer You must show
73. h to make up for normal self discharge Battery Tender can be left connected during the storage period and will automatically charge the battery if the voltage drops below a pre determined point See page 143 for the part numbers of Polaris products Battery Fluid Conventional Battery A poorly maintained battery will deteriorate rapidly Check the battery Mark Mark fluid level often Maintain the fluid level between the upper and lower level marks Add only distilled water Tap water contains minerals that are harmful to a battery 126 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 124 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 125 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 1s 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 maintai
74. handles at all times The passenger should never hold on to the operator Never secure a passenger to the vehicle or to the operator with a belt rope or similar device Make sure the passenger understands the importance of active riding When hill climbing or performing maneuvers a passenger should shift body weight in the same manner in which the driver shifts body weight For example the passenger should lean to the inside of a turn along with the operator and should always lean uphill when climbing and descending hills 71 OPERATION Driving on Slippery Surfaces Whenever riding on slippery surfaces such as wet trails or loose gravel or during freez ing weather follow these precautions 1 Slow down when enter ing slippery areas 2 Engage 4X4 before wheels begin to lose traction 3 Maintain a high level of alertness reading the trail and avoiding quick sharp turns which can cause skids 4 Correct a skid by turning the handlebars in the direction of the skid and shifting your body weight forward CAUTION Severe damage to drive train may occur if 4X4 is engaged while the wheels are spinning Always allow the rear wheels to stop spinning before engaging 4X4 or engage 4X4 before wheels begin to lose traction A WARNING Failure to exercise care when operating on slippery surfaces can result in loss of tire traction and cause loss of control accident and serious injury or death
75. he passenger seat lock out by attempting to release the cargo box dump lever If the dump lever releases the seat is not secure Repeat the set up procedure NOTE Ifthe lock out is not working properly do not allow a passenger to ride 8 the vehicle See your Polaris dealer for service To return the vehicle to single rider operation reverse all steps Always Locked lower the passenger backrest to the lowest position before folding it down into the cargo box Turn the operator backrest latches 1 4 turn to secure the locks 51 FEATURES AND CONTROLS Instrument Cluster Your ATV is equipped with an instrument cluster that senses vehicle speed from a sensor in the transmission The instrument cluster mea sures distance in miles as well as hours of operation It also includes a reverse speed limiter function that limits the ATV s speed to approxi mately 7 9 mph Refer to page 38 for additional information Speedometer Needle Speedometer Rider P amp LARIS Information Center NOTE n addition to showing vehicle speed the speedometer needle flashes when a warning condition exists CAUTION High water pressure may damage ATV components Wash the ATV 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
76. ication System Pressurized Wet Sump Driving System Type Automatic PVT Polaris Variable Transmission Front Suspension MacPherson strut with 8 2 21 cm travel Rear Suspension Progressive rate with 8 75 22 cm travel 146 SPECIFICATIONS Sportsman X2 700 EFI Transmission Automatic EBS Engine Braking System with E Z Shift H L N R P Gear Reduction Low 23 91 1 Gear Reduction Reverse 21 74 1 Gear Reduction High 828 1 Drive Ratio Front 3 82 1 Tires Pressure Front 25x8 12 5 psi Tires Pressure Rear 25x11 12 5 psi Brakes Front Single Control Hydraulic Disc Brakes Rear Single Control Hydraulic Disc Brake Auxiliary Foot Activated Hydraulic Disc Brake Parking Hydraulic lock all wheel Headlight 1 Single Beam on Headlight Pod 50 watt 2 Single Beam on Bumper 37 5 watt Taillights 1 826wats Brake Light 26 9 watts Instrument Cluster LCD Clutching EBS Models Altitude Shift Drive Clutch Driven Helix Weight Spring Clutch Spring Meters 0 1800 21 70 5 66 56 33 Feet 0 6000 PN 5632106 Red White Red BA500 PN 7043349 PN 3234452 EB 1800 3700 21 68 6000 12000 PN 5632128 PN 3234604 NOTE EBS models require no helix spring adjustment 147 SPECIFICATIONS Sportsman X2 800 EFI Maximum Weight Capacity 705 lbs 320 kg includes operator passenger c
77. ice cover inside the front box Have your dealer replace the filter after every 200 hours of operation and any time the fuel becomes contaminated with dirt or debris Do not attempt to clean the fuel filter Fuel Tank Cap Remove the fuel tank cap to add fuel to the fuel tank Use either leaded or unleaded gasoline with aminimum pump octane number of 87 R M 2 octane Do not use E 85 fuel 45 FEATURES AND CONTROLS Recoil Starter 500 EFI If the battery is too weak to start Handle the engine use the recoil starter Follow the starting procedures on page 63 cranking the engine with the recoil starter instead of the main key switch 1 Grasp the recoil starter rope handle tightly 2 Pull slowly so you can feel the engine strokes NOTE The rope will be harder to pull when the engine is on a compression stroke When a compression stroke is found continue pulling the rope just until the engine rolls past the stroke then stop pulling immediately 3 Allow the recoil rope to rewind into the recoil assembly then pull the rope abruptly and forcefully to start the engine Recoil Starter 4 Repeat all steps until the engine starts 5 Make sure the handle is fully seated on the housing CAUTION Extending the recoil starter rope until it stops can cause damage to the recoil assembly Do not extend the starter rope so far that it stops If the starter rope handle is not seated properly water may enter the
78. id Two fluid levels must be maintained on your vehicle the demand drive fluid and the ADC fluid See page 99 for demand drive fluid mainte nance Check and change the ADC fluid level at the intervals outlined in the Periodic Maintenance Chart beginning on page 85 Maintain the fluid level between the minimum and maximum marks on the reservoir We recommend the use of Polaris ADC Fluid See page 143 for the part numbers of Polaris products NOTE Do not use brake fluid Brake fluid will damage rubber components in the hydraulic system Gv Ue Uus parum 100 MAINTENANCE Active Descent Control ADC Fluid Fluid Level 1 Open the front box cover and pull open the access door 2 View the fluid level in the reservoir If the level is below the minimum mark remove the cap and add the recommended fluid 3 Reinstall the cap securely Secure the access door and box cover Fluid Change 1 Position the vehicle on a level surface Before performing the fluid change allow the vehicle to sit for at least 30 minutes 500 EFI 2 Thoroughly clean the areas around and on the ADC reservoir and bleeder valves one on each side of the differential 3 Remove the reservoir cap and diaphragm assembly Use a shop towel or suction tool to remove debris from the fluid and reser voir NOTE Debris in the reservoir may result in inadequate bleeding and reduced performance of the system 4 Fillthe reservoir to the maximum line
79. il will be lost if the crank ey case drain is opened co ee 7 117 MAINTENANCE Vehicle Immersion CAUTION If your vehicle becomes immersed major engine damage can result if the machine is not thoroughly inspected Take the vehicle to your dealer before starting the engine 118 If it s impossible to take your ATV to a dealer before starting it fol low the steps outlined below Move the ATV to dry land or at the very least to water below the footrests Check the air box If water is present dry the air box and replace the filter with a new filter Remove the spark plug Turn the engine over several times using the electric start Dry the spark plug Reinstall the plug or install a new plug Attempt to start the engine If necessary repeat the drying proce dure Take the ATV to your dealer for service as soon as possible whether you succeed in starting it or not If water has been ingested into the PVT follow the procedure on page 122 for drying out the PVT MAINTENANCE Spark Arrestor A WARNING Failure to heed the following warnings while servicing the spark arrestor could result in serious injury or death 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 Remove any combustible materials from the area Wear eye protection and leather work gloves Do not stand behind o
80. in wet conditions gt Brake pad wear 10H Monthly 100 160 Inspect periodically u Battery 20H Monthly 200 320 Check terminals clean test gt Rear gearcase oil 25H Monthly 250 400 Inspect level change yearly if equipped gt Transmission oil 25H Monthly 250 400 Inspect level change yearly gt Demand drive fluid 25 H Monthly 250 400 Inspect level change yearly gt Engine breather 25 H Monthly 250 400 Inspect clean if needed E filter if equipped gt General 50 H 3M 500 800 Lubricate all fittings pivots lubrication cables etc Shift linkage 50H 6M 500 800 Inspect lubricate E Steering 50H 6M 500 800 Lubricate gt Front suspension 50 H 6M 500 800 Lubricate gt Rear suspension 50H 6M 500 800 Lubricate E Throttle Cable 50H 6M 500 800 Inspect adjust lubricate E ETC Switch replace if necessary E Throttle Body 50H 6M 500 800 Inspect duct for proper seal Intake Duct ing air leaks Drive belt 50H 6M 500 800 Inspect adjust replace as needed Cooling system 50H 6M 1000 1600 Inspect coolant strength if applicable seasonally pressure test system yearly gt Engine oil change 100 H 6M 1000 1600 Perform a break in oil change at one month gt Oil filter change 100 H 6M 1000 1600 Replace with oil change 87 MAINTENANCE Periodic Maintenance Chart Item Main
81. ion timing See your dealer Mechanical failure See your dealer Loose ignition connections Check all connections and tighten Water present in fuel Replace with fresh recommended fuel 140 Engine Pings or Knocks Possible Cause TROUBLESHOOTING Solution Poor quality or low octane fuel Replace with recommended fuel Incorrect ignition timing See your dealer Incorrect spark plug gap or heat range Set gap to specs or replace plugs Engine Runs Irregularly Stalls or Misfires Possible Cause Solution Fouled or defective spark plug s Inspect clean and or replace spark plug s Worn or defective spark plug wires See your dealer Incorrect spark plug gap or heat range Set gap to specs or replace plugs Loose ignition connections Check all connections and tighten Water present in fuel Replace with new fuel Low battery voltage Recharge battery to 12 8 VDC Kinked or plugged fuel tank vent line Inspect and replace Incorrect fuel Replace with recommended fuel Clogged air filter Inspect and clean or replace Reverse speed limiter malfunction See your dealer Electronic throttle control malfunction See your dealer Other mechanical failure Possible Lean Fuel Cause Low or contaminated fuel See your dealer Solution Add or change fuel clean the fuel system Kinked or plugged fuel tank v
82. ive Grease 2871515 Premium U Joint Lube 3 0z 89 ml cartridge 2871551 Premium U Joint Lube 14 0z 414 ml cartridge 2871329 Dielectric Grease Nyogel 2872073 Chain Lube Aerosol 6 25 0z 185 ml 2872348 Chain Lube Aerosol 16 0z 473 ml Additives Miscellaneous 2871326 Carbon Clean Plus 2870652 Fuel Stabilizer 2872189 DOT 4 Brake Fluid 2871956 Loctite 565 Thread Sealant 2859044 Polaris Battery Tender Charger 143 SPECIFICATIONS Sportsman X2 500 EFI Maximum Weight Capacity 705 Ibs 320 kg includes operator passenger cargo accessories Dry Weight 798 Ibs 362 kg base model Front Rack Storage Box Capacity 90 Ibs 41 kg Rear Storage Box Capacity 400 Ibs 181 kg Receiver Hitch Tongue Capacity 120 Ibs 55 kg Rear box capacity and tongue weight not to exceed 400 Ibs 181 kg Receiver Hitch Towing Capacity 1225 lbs 557 kg on level ground Overall Length 93 in 236 cm Overall Width 48 in 122 cm Overall Height 48 in 122 cm Wheelbase 57 in 145 cm Ground Clearance 11 in 28 cm Minimum Turning Radius 82 in 208 cm unloaded Fuel Capacity 6 gal 22 7 1 Engine Oil Capacity 2 qts 1 9 1 Coolant Capacity 2 7 qts 2 5 1 Demand Drive Fluid Capacity 9 3 oz 275 ml Transmission Oil Capacity 32 oz 948 ml Engine EHSOPLE Displacement 499 cc Bore x Stroke 92 x 75 Alte
83. ke sudden throttle changes If your vehicle becomes immersed and it s impossible to take it to a dealer before starting it follow the steps described on page 118 Have the vehicle serviced by your dealer at the first opportunity 79 OPERATION Driving Over Obstacles 1 Be alert Look ahead and learn to read the terrain you re traveling on Be constantly alert for hazards such as logs rocks and low hang ing branches 2 Avoid operating over large obstacles such as rocks and fallen trees when possible If unavoidable use extreme caution 3 Always have a passenger dismount before operating over an obsta cle that could cause a fall from the vehicle or vehicle tipover A WARNING Severe injury or death can result if your vehicle comes in contact with a hidden obstacle Not all obstacles are immediately visible Travel with caution in unfamiliar terrain 80 OPERATION Parking on an Incline Avoid parking on an incline if possible If it s unavoidable follow these precautions l 2 3 4 Stop the engine Place the transmission in PARK Lock the parking brake Always block the rear wheels on the downhill side 81 OPERATION Driving in Reverse A WARNING Failure to use caution when operating in reverse can result in serious injury or death Before shifting into reverse always check for obstacles or people behind the vehicle When it s safe to proceed back slowly Do not u
84. l Apply the single lever brakes Lock the parking brake when fully stopped Dismount on the uphill side of the vehicle or on the left if the vehicle is pointing straight uphill Have a passenger dismount first then the operator may dismount Turn the ATV around and remount following the procedure described in the owner s manual See page 76 If the ATV begins rolling backwards Keep operator and passenger body weight uphill Never apply engine power Never apply the rear brake while rolling backwards Apply the single lever brake gradually When fully stopped apply the foot brake as well and then lock the parking brake Dismount on the uphill side of the vehicle or on the left if the vehicle is pointing straight uphill Have a passenger dismount first then the operator may dismount Turn the ATV around and remount following the procedure described in the owner s manual See page 76 32 SAFETY Rider Safety A WARNING POTENTIAL HAZARD Improperly operating over obstacles WHAT CAN HAPPEN Operating over obstacles could cause loss of control or overturn HOW TO AVOID THE HAZARD Before operating in a new area check for obstacles Avoid operating over large obstacles such as rocks and fallen trees when possible If unavoidable use extreme caution and always follow proper procedures as outlined in the owner s manual Always have a passenger dismount before operating over an obstacle
85. lashes Release the button 4 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 NOTE If you scroll past the intended number press and hold the button until the hours cycle back to zero 5 When the desired setting is displayed wait until the wrench icon stops flashing The new service interval is now programmed Miles Kilometers toggle The display in the tripmeter and odometer can be changed to display either standard or metric units of measurement 1 Enter the diagnostic mode 2 Toggle to the screen that displays either kilometers KM or miles MP 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 57 FEATURES AND CONTROLS Instrument Cluster Rider Information Center Downloading Codes The EFI diagnostic mode is for informational purposes only Please see your Polaris dealer for all major repairs See page 59 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 the ON position 2 Turm the key switch off and on three times in less than five seconds The word WAIt will appear on the screen 3 The Check Engine icon will blink once pause then blink twice blink
86. latch 3 Grasp the entire taillight assembly and pull it away from the vehicle 4 Remove the harness connector from the back of the light assem bly 5 Turn the lamp counterclockwise to remove it r m 6 Apply dielectric grease to the uus socket and install the new lamp AAN 7 Reinstall the harness connector 8 Test the light for proper operation B 9 ino Reinstall the taillight assembly 10 Reinstall the two screws 115 MAINTENANCE Spark Plugs Spark Plug Recommendations CAUTION Using non recommended spark plugs can result in serious engine damage Always use Polaris recommended spark plugs Refer to the specifications section beginning on page 144 for the recom mended spark plug type and gap for your vehicle Torque spark plugs to specification Plug Condition Torque Specification New Spark Plug 9 11 ft Ibs 12 15 Nm Previously Installed Spark Plug 17 20 ft Ibs 23 27 Nm Spark Plug Inspection Spark plug condition is indicative of engine operation Check the spark plug firing end condition after the engine has been warmed up and the vehicle has been driven at higher speeds Immediately check the spark plug for correct color See page 117 A WARNING A hot exhaust system and engine can cause serious burns Wear protective gloves when removing a spark plug for inspection 1 Rotate the spark plug cap 1 4 turn and pull it off the spark plug 2 Using th
87. letely to keep the angle and depth of the stick consis tent 4 Remove the dipstick and check the oil level Maintain the oil level in the safe range Do not overfill NOTE Dueto the dipstick entry angle into the crankcase the oil level will read higher on the bottom side of the dipstick Always read the level on the upper surface of the dipstick 5 After reinstalling the dipstick seat the lever lock 92 Dipstick Check Level on Top Side MAINTENANCE Engine Oil Cil and Filter Change 500 EFI A CAUTION Hot oil can cause serious burns to skin Do not allow hot oil to contact skin Always change the oil and filter at the intervals outlined in the Periodic Maintenance Chart beginning on page 85 1 Position the vehicle on a level surface 2 Start the engine Allow it to idle for two to three minutes 3 Stop the engine 4 Clean the area around the drain plug 5 Place a drain pan under the oil tank 6 Remove the drain plug Allow the oil to drain completely 7 Install a new sealing washer on the drain plug NOTE The sealing surfaces on drain plug and crankcase should be clean and free of burrs nicks or scratches 8 Reinstall the drain plug Torque to 14 17 ft Ibs 19 23 Nm 9 Disconnect the lower oil deliv ery hose and remove the screen fitting from the oil tank Clean Alignment Mark the fitting NOTE The fitting threads must be sealed with LOCTITE PST 505 or P
88. lined in the Periodic Maintenance Chart beginning on page 85 We rec ommend the use of Demand Drive LT Premium Fluid Use of other fluids may result in improper operation of components See page 143 for the part numbers of Polaris products Maintain the fluid level at Fill the bottom of the fill hole Plug threads See below for capacity The fill plug is located on the right side of the demand drive unit The drain plug is located on the bottom right side of the unit Fill Level Demand Drive Capacities Demand Drive with ADC 9 3 oz 275 ml 99 MAINTENANCE Front Gearcase Demand Drive Fluid Fluid Level 1 Position the vehicle on a level surface 2 Remove the fill plug Check the fluid level 3 Add the recommended demand drive fluid as needed to bring the level to the bottom of the fill hole threads 4 Reinstall the fill plug Torque to 8 10 ft Ibs 11 14 Nm Fluid Change Position the vehicle on a level surface Remove the fill plug Place a drain pan under the demand drive unit Remove the drain plug Allow the fluid to drain completely Clean and reinstall the drain plug Torque to 11 ft Ibs 15 Nm Add the recommended fluid See page 99 for capacity Maintain the fluid level at the bottom of the fill hole threads Reinstall the fill plug Torque to 8 10 ft Ibs 11 14 Nm 8 Check for leaks 9 Dispose of used fluid properly Active Descent Control ADC Flu
89. m of the crankcase can lead to engine damage and must be drained Water accu mulation increases as outside temperature decreases See your Polaris dealer for engine heater kits which provide quicker warm ups and easier starting in colder weather 63 OPERATION Hauling Cargo A WARNING Overloading the vehicle or carrying or towing cargo improperly can alter vehicle handling and may cause loss of control or brake instability Always follow these precautions when hauling cargo Never exceed the stated load capacity for this vehicle Never carry cargo in the rear box when operating the ATV in the 2 up mode with a passenger REDUCE SPEED AND ALLOW GREATER DISTANCES FOR BRAKING WHEN HAULING CARGO REDUCE SPEED AND CARGO to maintain stable driving conditions when operating over rough or hilly terrain WEIGHT DISTRIBUTION in the cargo bed should be as far forward and as low as possible Carrying a high load raises the center of gravity and creates a less stable operating condition Reduce load weight when cargo is high When handling off centered loads that cannot be centered secure the load and operate with extra caution SECURE ALL LOADS BEFORE OPERATING Unsecured loads may shift and create unstable operating conditions which could result in loss of control of the vehicle Always be sure that the cargo bed is lowered and latched before moving the vehicle USE EXTREME CAUTION when operating with loads extending beyond th
90. n angle which would cause the vehicle to lean sharply to one side Drive straight downhill Always follow proper procedures for crossing the side of a hill Do not cross a hillside with a passenger on board Avoid hills with exces sively slippery or loose surfaces Shift your weight uphill Never attempt to turn the ATV around on any hill until you ve mastered on level ground the turning technique outlined in this manual Avoid crossing the side of a steep hill when possible Always use proper procedures if you stall or roll backwards while climbing a hill To avoid stalling maintain a steady speed when climbing a hill If you stall or roll backwards follow the special pro cedure for braking described in this manual Always dismount on the uphill side or to either side if the ATV is pointed straight uphill Turn the ATV around and remount following the procedure described in this manual Always check for obstacles before operating in a new area Never attempt to operate over large obstacles such as rocks or fallen trees Always follow proper procedures when operating over obstacles as described in this manual Always be careful of skidding or sliding On slippery surfaces like ice travel slowly and use extra caution to reduce the chance of skid ding or sliding out of control Avoid operating the ATV through deep or fast flowing water If it s unavoidable travel slowly balance your weight carefully avoid sud den movement
91. nd in the owner s manual Always use original equipment size and type when replacing tires Make sure the wheels are installed properly Always replace tires when the tread depth measures 1 8 3 mm or less Tire Tread Depth Always replace tires 1 8 3 mm t when tread depth is worn to 1 8 3 mm or less tp S 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 Removal Stop the engine Place the transmission in PARK Lock the parking brake Loosen the wheel nuts slightly pho cep Nd Elevate the side of the vehicle by placing a suitable stand under the footrest frame a Remove the wheel nuts 7 Remove the wheel 107 MAINTENANCE Tires Wheel Installation A WARNING Improperly installed wheels can adversely affect tire wear and vehicle handling which can result in serious injury or death Always ensure that all nuts are torqued to specification Do not service axle nuts that have a cotter pin installed See your Polaris dealer 1 Place the transmission in PARK Lock the parking brake 3 Place the wheel on the hub with the valve stem toward the outside and rotation arrows on the tire pointing toward forward rotation 4 Install the wheel nuts and finger tighten them 5 Lower the vehicle to the ground 6 Torque the wheel nuts to s
92. ng or descending a hill See page 49 Always check the terrain carefully before ascending any hill Never climb hills with excessively slippery or loose surfaces Shift body weight uphill A passenger should also shift body weight uphill Never open the throttle suddenly while traveling uphill The ATV could flip over backwards Never go over the top of any hill at high speed An obstacle a sharp drop or another vehicle or person could be on the other side of the hill EI Never operate with the differential unlocked lt gt while operating on a hill or other irregular terrain Always move the 4X4 switch to ADC 4X4 before ascending or descending a hill See pages 39 and 49 29 SAFETY Rider Safety A WARNING POTENTIAL HAZARD Traveling downhill improperly WHAT CAN HAPPEN Improperly descending a hill could cause loss of control or overturn HOW TO AVOID THE HAZARD Always follow proper as procedures for traveling down a ey hills as described in the owner s manual See page 75 Never operate with the differential unlocked lt gt while operating on a hill or other irregular terrain Always move the 4X4 switch to ADC 4X4 before ascending or descending a hill See pages 39 and 49 Always check the terrain carefully before descending a hill Always descend a hill with the transmission in forward gear Do not descend a hill with the transmission in neutral Shift body weight uphill A passenge
93. ngine and allow it to warm up Shift the transmission into gear Check your surroundings and determine your path of travel Release the parking brake Slowly depress the throttle with your right thumb and begin driving 12 Drive slowly Practice maneuvering and using the throttle and 68 brakes on level surfaces OPERATION Turning the Vehicle Both rear wheels drive equally at all times except when operating in 2X4 mode with the differential unlocked This means that the outside wheel must travel a greater distance than the inside wheel when turning and the inside tire must slip traction slightly 1 Slow down 2 Never turn quickly when carrying a passenger or cargo 3 Steer in the direction of the turn 4 Keep both feet on the footrests 5 Lean your upper body to the inside of the turn while supporting your weight on the outer footrest NOTE This technique alters the balance of traction between the rear wheels allowing the turn to be made smoothly 6 The same leaning technique should be used for turning in reverse NOTE Practice making turns at slow speeds before attempting to turn at faster speeds A WARNING Turning at sharp angles or at excessive speeds can result in vehicle overturn and lead to serious injury Avoid turning at sharp angles Never turn at high speeds 69 OPERATION Driving with a Passenger l NOTE Footwell risers should be installed 70 Mak
94. ning a sealed battery is to keep it fully charged Since the battery is sealed and the sealing strip cannot be removed you must use a voltmeter or multimeter to measure DC voltage A WARNING An overheated battery may explode causing severe injury or death Always watch charging times carefully Stop charging if the battery becomes very warm to the touch Allow it to cool before resuming charging For a refresh charge follow all instructions carefully 1 Check the battery voltage with a voltmeter or multimeter A fully charged battery will register 12 8 V or higher 2 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 NOTE When using an automatic charger refer to the charger manufacturer s instructions for recharging When using a constant current charger use the guidelines on the next page for recharging 127 MAINTENANCE Battery Battery Charging Sealed Battery NOTE Always verify battery condition before and 1 2 hours after the end of charging harge Tim State of e arge Voltage Action Using constant current Charge charger standard amps specified on top of battery 100 12 8 13 0 volts None check at 3 mos from date of manufacture None required 75 100 12 5 12 8 volts May need slight charge if no charge given check in 3 months 3 6 hours 50 75 12 0 12 5 volts Needs charge 5
95. nventional batteries install the battery vent tube sealed bat teries do not have a vent tube NOTE The vent tube must be free of obstructions and securely installed Route the tube away from the frame and vehicle body to prevent con tact with electrolyte A WARNING Battery gases could accumulate in an improperly installed vent tube and cause an explosion resulting in serious injury or death Always ensure that the vent tube is free of obstructions and is securely installed as recommended 4 Onconventional batteries coat the terminals with dielectric grease or petroleum jelly Connect and tighten the red positive cable first Connect and tighten the black negative cable last Install the battery cover Tighten the battery hold down bolt Verify that cables are properly routed NOTE Cables should be safely tucked away at the front and rear of the bat tery 0 uot 125 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 NOTE Power plug leads may need to be bent down so that the battery cover can be installed NOTE Battery charge can be maintained by using a Polaris Battery Tender charger or by charging about once a mont
96. o Pantone 426C POLARIS The Way Out 500 EFI 700 EFI 800 EFI 2008 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 ml 7 ai Pantone 426C AWARNING Improper vehicle use can result in SEVERE INJURY or DEATH ALWAYS USE NEVER USE NEVER CARRY NEVER USE AN APPROVED ON PUBLIC MORE THAN WITH DRUGS HELMET AND ROADS ONE OR ALCOHOL PROTECTIVE GEAR PASSENGER FOR OPERATOR AND PASSENGER NEVER operate e without proper training or instruction e at speeds too fast for your skills your passenger s skills or the conditions e on public roads a collision can occur with another vehicle e with more than one passenger passengers affect balance and steering and increase risk of losing control e with a passenger under the age of 12 THE OPERATOR MUST ALWAYS use proper riding techniques to avoid vehicle overturns on hills and rough terrain and in turns avoid paved surfaces pavement may adversely affect handling and control e reduce speed and use extra caution at all times when carrying a passenger have passenger dismount when conditions require e make sure passenger reads and understands this label and passenger safety label LOCATE AND READ OWNER S MANUAL FOLLOW ALL INSTRUCTIONS AND WARNINGS For your nearest Polaris dealer POLARIS ca 1 800 POLARIS
97. operator with a belt rope or similar device Never carry more than one passenger on this 2 up ATV Always make sure the passenger seat lock out is functioning properly before carrying a passenger Never permit a guest to operate the ATV unless the guest has read this manual and all product labels and has completed a certified safety training course Always keep both hands on the handlebars and both feet on the foot rests of the ATV during operation A passenger should always be seated in the passenger seat with both feet on the footrests and both hands on the passenger grab handles at all times The passenger should never hold on to the operator Always avoid operating an ATV on paved surfaces including side walks driveways parking lots and streets Never operate an ATV on a public street road or highway including a dirt or gravel road 17 SAFETY Rider Safety 18 Never operate an ATV without wearing an approved helmet that fits properly Always wear eye protection goggles or face shield gloves boots a long sleeved shirt or jacket and long pants A passenger s helmet should have a rigid chin guard Never consume alcohol or drugs before or while operating an ATV Never operate at excessive speeds Travel at speeds appropriate for your skills your passenger s skills and operating conditions Never attempt jumps or other stunts Always inspect your ATV before each use to make sure it s in safe operating
98. ot aggressively apply the auxiliary brake when going forward The rear wheels may skid and slide sideways causing loss of control and serious injury or death The auxiliary foot brake is located Auxiliary Foot Brake on the inside of the right footrest Operate this brake with your right foot NOTE Ifthe rear wheels slide while using the auxiliary brake reduce brake pedal pressure to brake the rear wheels with out skidding Brake Fluid Level Check the brake fluid level frequently for the auxiliary brake system The reservoir is located under the seat Maintain the fluid level between the maximum and minimum marks 44 FEATURES AND CONTROLS Automatic Transmission Gear Selector The transmission gear selector is Gear g located on the right side ofthe vehicle Selector 952 High Gear L Low Gear N Neutral R Reverse P Park Whenever the ATV is left unattended always place the transmission in PARK and lock the parking brake CAUTION Shifting gears with the engine speed above idle or while the vehicle is moving could cause transmission damage To change gears stop the vehicle and with the engine idling move the lever to the desired gear Belt Life To extend belt life use low forward gear in heavy pulling situations and when operating at less than seven miles per hour for extended periods of time Fuel Filter 500 EFI The in line fuel filter is located under the rubber serv
99. pecification Wheel Nut Torque Specifications Check the wheel nut torques occasionally and when they ve been loos ened for service Nut Type Nut Torque Lug Nut 90 ft Ibs 122 Nm 2 Piece Flange Nut 27 ft lbs 37 Nm 108 MAINTENANCE Air Filter Pre Filter 1 Remove the seat Main Filter 2 Release the air box cover clips and remove the air box cover 3 Loosen the clamp and remove the filter 4 Remove the fabric type pre filter from the main filter Wash the pre filter in soapy water then rinse and let dry 5 Reinstall the pre filter over the main filter NOTE Install a new main filter if needed 6 Reinstall the filter into the air box and tighten the clamp Do not over tighten the clamp as filter dam age could occur 7 Reinstall the air box cover and the seat 109 MAINTENANCE Breather Filter Hose 500 i The breather filter is on the hose that runs between the engine and air box l 2 4 2 Remove the left side HAYS AD panel See page 106 suf l Remove the hose Ui clamps from the fil Breather Filfer ES ter and pull the filter out of the hoses Inspect the filter for debris Blow gently through the filter in the direction of the arrow to check for clogging Replace a damaged or clogged filter Check the hoses for cracks deterioration abrasion or leaks Replace as needed Reinstall the filter and hose clamps NO
100. pward or downward Tighten the screw 113 MAINTENANCE Lights Headlight Housing Replacement 1 Remove the two screws on the lower front corners of the headlight pod Lift the pod slightly while depressing the tabs at the rear of the pod 3 Lift the pod cover and disconnect the speedometer harnesses from the speedometer 4 Unplug the headlamp from the wiring harness 5 Use a small screwdriver to remove the o rings from the headlight mounting tabs 6 Pull the headlight housing up to release it from the locking tabs 7 Lift the adjusting knob up to remove it from the locking tabs 8 Carefully pull the assembly up and out of the pod 9 Reverse the steps to install the new housing and reassemble the pod NOTE The distance from the head lamp parting line to the end of the adjustment knob stop is 5 1 8 13 cm 10 Adjust the headlight aim by l turning the adjusting knob 114 MAINTENANCE Lights Lower Headlamp Replacement l Turn the back of the headlight harness counterclockwise and pull the harness assembly away from the headlight assembly Remove the headlamp and install the new headlamp Reinstall the harness assembly into the headlight assembly Turn the headlight harness clock wise to secure the headlamp Taillight Brakelight Worklight if equipped Lamp Replacement 1 Open the tailgate 2 Remove the two screws near the tailgate
101. r in front of the vehicle while purging Never run the engine in an enclosed area Exhaust contains poisonous carbon monoxide gas Never go under the vehicle while it s inclined Use the following procedure to periodically purge accumulated carbon from the exhaust pipe muffler 1 Remove the arrestor clean out plug from the bottom of the muffler 2 Place the transmission in PARK 3 Start the engine 4 Quickly squeeze and release the throttle lever several times to purge carbon from the system Clean Out Plug 5 Ifcarbon comes out of the exhaust cover or plug the exhaust outlet Wear protective gloves 6 Lightly tap on the exhaust pipe with a rubber mallet while repeating step 4 7 Ifparticles are still suspected to be in the muffler elevate the rear of the vehicle one foot 30 cm higher than the front Block the wheels 8 Place the transmission in PARK Lock the parking brake Repeat steps 4 to 6 until no more particles are expelled 9 Stop the engine Allow the arrestor to cool 10 Reinstall the arrestor plug and remove the exhaust outlet cover or plug 119 MAINTENANCE PVT System A WARNING Failure to comply with the instructions in this warning can result in severe injury or death Do not modify any component of the PVT system Doing so may reduce its strength so that a failure may occur at a high speed The PVT system has been precision balanced Any modification will cause
102. r manual to your dealer each time your vehicle is serviced This will provide you and future owners with an accurate log of maintenance and ser vices performed DATE MILES KM OR HOURS TECHNICIAN SERVICE PERFORMED COMMENTS 156 MAINTENANCE LOG DATE MILES KM OR HOURS TECHNICIAN SERVICE PERFORMED COMMENTS 157 INDEX 0 10 4X4 Switch 0 2 38 A Accessories 006 134 Active Descent Control Fluid 100 101 Active Descent Control System 49 ADC System 004 49 Age Restrictions 14 Air Filters 2 vec pp pem 109 All Wheel Drive System 47 48 Auxiliary Foot Brake 104 B Battery 30 35 06 0 rr 123 128 Charging Conventional 127 Charging Sealed 127 128 Conventional 123 Fluid Conventional 126 Installation ss 125 Removals 521369 124 Stora Des coe p y RES RD 126 Belt Efe ecoute tra 45 ho PUTEM 13 Brake Fluid Auxiliary Foot Brake 44 Brake Fluid Main Brake System 42 Brake Lever 00 41 Brake Foot 44 104 Brake Hand Lever 104 Brake Parking 43 Brakelight Lamp Replacement 115 Brakes3 552 supo eate bos 104 Break In Period 61 Breather Filter 110 Breather Hose
103. r should also shift body weight uphill Never travel down a hill at high speed Avoid traveling down a hill at an angle which would cause the vehicle to lean sharply to one side Travel straight down the hill when possible 30 SAFETY Rider Safety A WARNING POTENTIAL HAZARD Improperly crossing hills and turning on hills WHAT CAN HAPPEN Improperly crossing or turning on hills could cause loss of control or overturn HOW TO AVOID THE HAZARD Never attempt to turn the ATV around on any hill until you ve mastered the turning technique on level ground as described in the owner s manual See page 76 Use extra caution when turning on any hill Do not cross a hillside with a passenger on board Avoid crossing the side of a steep hill When crossing the side of a hill Always follow proper procedures as described in the owner s manual Avoid hills with excessively slippery or loose surfaces Shift your weight to the uphill side of the ATV 31 SAFETY Rider Safety A WARNING POTENTIAL HAZARD Stalling rolling backwards or improperly dismounting while climbing a hill WHAT CAN HAPPEN The vehicle could overturn HOW TO AVOID THE HAZARD Maintain steady speed when climbing a hill Always move the 4X4 switch to ADC 4X4 before ascending or descending a hill See page 49 If all forward speed is lost Lean forward to keep body weight uphill A passenger should also lean uphil
104. recoil housing and damage components Make sure the handle is fully seated on the recoil housing especially when traveling in wet areas 46 FEATURES AND CONTROLS All Wheel Drive System The All Wheel Drive system is controlled by the 4X4 switch ADC 4X4 Mode When the switch is on ADC 4X4 4 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 49 4X4 Mode When the switch is on 4X4 the ATV is in 4X4 and the 4X4 indicator light in the instrument cluster will be on ADC 4x4 4x4 2x4 4X4 Switch 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 NOTE The override switch allows activation of 4X4 in reverse if the 4X4 switch is on See page 38 2X4 Mode When the switch is on 2X4 the ATV is in two wheel drive at all times 47 FEATURES AND CONTROLS All Wheel Drive System Engaging 4X4 The 4X4 switch may be turned on or off while the vehicle 1s moving Initially the vehicle s electronic system will not enable 4X4 until the engine RPM is below 3100 Once enabled 4X4 remains enabled until the 4X4 switch is turned off If the switch is turned off whil
105. reen to check battery voltage level Tachometer Screen View the tachometer to check engine speed 4X4 Diagnostic Screen The gauge indicates whether or not current is flowing through the all wheel drive coil This screen is for informational purposes only Please see your dealer for all major repairs Gear Circuit Diagnostic Screen This screen displays the resistance value in ohms being read at the gear switch input of the gauge This screen is for informational purposes only Please see your dealer for all major repairs Programmable service interval When the hours 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 57 NOTE The service interval is programmed at 50 hours at the factory 56 FEATURES AND CONTROLS Instrument Cluster Rider Information Center Diagnostic Mode Programmable service interval To enable or disable the service interval 1 Enter the diagnostic mode 2 Toggle to the service interval screen 3 Press and hold the mode button for about 7 seconds until either ON or OFF appears in the Rider Information Center depending on your preference To reset the service interval 1 Enter the diagnostic mode 2 Toggle to the service interval screen 3 Press and hold the mode button for 2 3 seconds until the wrench icon f
106. rnator Output 350 w Compression Ratio 10 2 1 Fuel System Electronic Fuel Injection Ignition System Electronic Ignition Ignition Timing 10 1 BTDC idle Spark Plug NGK BKR6E 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 8 75 22 cm travel 144 SPECIFICATIONS Sportsman X2 500 EFI Transmission Automatic EBS Engine Braking System with E Z Shift H L N R P Gear Reduction Low 23 91 1 Gear Reduction Reverse 21 74 1 Gear Reduction High 10 57 1 Drive Ratio Front 3 82 1 Tires Pressure Front 25x8 12 5 psi Tires Pressure Rear 25x11 12 5 psi Brakes Front Single Control Hydraulic Disc Brakes Rear Single Control Hydraulic Disc Brake Auxiliary Foot Activated Hydraulic Disc Brake Parking Hydraulic lock all wheel Headlight 1 Single Beam on Headlight Pod 50 watt 2 Single Beam on Bumper 37 5 watt Taillights 8 26 watts Brake Light 26 9 watts Instrument Cluster LCD Clutching EBS Models Altitude Shift Drive Clutch Driven Helix Weight Spring Clutch Spring Meters 0 1800 10 WH Blue Green Yellow EBS Feet 0 6000 PN 5630710 PN 7041
107. rosive elements 1 Wash chrome wheels frequently Use a mild detergent Never use abrasive cleaners on plated or painted surfaces 2 Rinse well with clear water Soap detergents salt dirt mud and other elements can cause corrosion 3 Polish the clean chrome wheels periodically Use an automotive grade chrome polish 4 Routinely and liberally apply a weather resistant wax to each pol ished chrome wheel Choose a product suitable for chrome finishes Read and follow the product labels and instructions Removing Corrosion If light rust is found on the chrome finish use steel wool 0000 OTT grade to 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 131 MAINTENANCE Cleaning and Storage Storage Tips CAUTION 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 129 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 NOTE Carbon Clean removes water from fuel systems stabilizes fuel and removes carbon deposits from pistons rings valves and exhaust sys tems
108. ry or death Have an authorized Polaris dealer perform these services Perform all services at whichever maintenance interval is reached first Item Maintenance Interval Remarks whichever comes first Hours Calendar Miles Km Steering Pre Ride Make adjustments as needed See Pre Ride Front suspension Pre Ride Checklist on page 62 Rear suspension Pre Ride Tires Pre Ride Brake fluid level Pre Ride Brake lever travel Pre Ride Brake system Pre Ride Passenger seat Pre Ride lock out Wheels fasteners Pre Ride Frame fasteners Pre Ride Engine oil level Pre Ride gt Air filter pre filter Daily Inspect clean often replace E as needed gt Air box sediment Daily Drain deposits when visible tube Coolant Daily Check level daily change if applicable coolant every 2 years gt ADC fluid Daily Check level daily add as ADC models needed Headlight taillight Daily Check operation apply worklight dielectric grease if replacing lamps 86 Periodic Maintenance Chart MAINTENANCE Item Maintenance Interval Remarks whichever comes first Hours Calendar Miles Km gt Air filter Weekly Inspect replace as needed E main element Recoil housing Weekly Drain water as needed if applicable check often if operating
109. s 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 123 MAINTENANCE Battery A WARNING Improperly connecting or disconnecting battery cables can result in an explosion and cause serious injury or death When removing the battery always disconnect the negative black cable first When reinstalling the battery always connect the negative black cable last Battery Removal Loosen the battery hold down bolt Remove the battery cover On conventional batteries remove the battery vent tube Disconnect the black negative battery cable first Disconnect the red positive battery cable last Quoc E x93 Nok Lift the battery out of the ATV Be careful not to tip a conventional battery sideways which could spill electrolyte CAUTION 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 124 MAINTENANCE Battery Battery Installation Using a new battery that has not been fully charged can damage the bat tery and result in a shorter life It can also hinder vehicle performance Follow the battery charging instructions on page 127 before installing the battery 1 Ensure that the battery is fully charged 2 Place the battery in the battery holder 3 With co
110. s and maintain a slow and steady forward motion Do not make sudden turns or stops and do not make sudden throttle changes Wet brakes may have reduced stopping ability Test the brakes after leaving water If necessary apply them lightly several times to allow friction to dry out the pads 19 SAFETY Rider Safety Always check for obstacles or people behind the ATV before operat ing in reverse Be aware that a passenger can obstruct your view When it s safe to proceed in reverse move slowly and avoid turning at sharp angles Always use the size and type of tires specified for your ATV and always maintain proper tire pressure Never modify an ATV through improper installation or use of acces sories Never exceed the stated load capacity for your ATV 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 FOR MORE INFORMATION ABOUT ATV SAFETY call the Consumer Product Safety Commission at 1 800 638 2772 or visit www cpsc gov visit www atvsafety org or call Polaris at 1 800 342 3764 20 SAFETY Rider Safety Equipment Modifications We are concerned for the safety of our customers and for the general public Therefore we strongly recommend that consumers do not install on a Polaris ATV any equipment that may increase the speed or power of the vehicle or make any other modifica
111. se the override switch unless additional power is required for vehicle movement Use with caution Avoid backing on inclines and avoid turning at sharp angles CAUTION 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 Operate the throttle just enough to maintain a desired speed 82 OPERATION Driving in Reverse Follow these precautions when operating in reverse 1 Always check for obstacles or people behind the vehicle Be aware that a passenger can obstruct your view Always avoid backing downhill Back slowly Apply the brakes ightly for stopping Avoid turning at sharp angles Never open the throttle suddenly NOTE Your Polaris ATV is equipped with a reverse speed limiter Use the override button with caution as rearward vehicle speed is greatly increased Do not operate at wide open throttle Apply just enough throttle to maintain a desired speed 9 t Bop 83 EMISSION CONTROL SYSTEMS Noise Emission Control System Do not modify the engine intake or exhaust components as doing so may affect compliance with U S A EPA noise control requirements 40 CFR 205 and local noise level requirements Operation on Public Lands in the U S A Your Polaris vehicle has a spark arrestor that was tested and qualified to be in accordance with the USDA Forest Service Standard 5100 1C Fed eral law requires
112. sible Do not cross a hillside with a passenger on board Follow proper procedures as outlined in the owner s manual Sidehilling can be dangerous and should be avoided if at all possible If you encounter a situation where sidehilling 1s necessary follow these precautions 1 Slow down 2 Ifoperating in 2X4 mode make sure the differential is locked 3 Donotcross a hillside with a passenger on board Ask the passenger to dismount and walk across the hillside before remounting the vehicle 4 Lean into the hill transferring your upper body weight toward the hill while keeping your feet on the footrests 5 Steer slightly into the hill to maintain vehicle direction NOTE Ifthe vehicle begins to tip quickly turn the front wheel downhill if possible or dismount on the uphill side immediately 74 OPERATION Driving Downhill 15 Maximum A WARNING Excessive speed when traveling downhill can cause loss of control and serious injury or death Slow down Applying the brakes too firmly may cause the rear wheels to lock which could result in loss of control and serious injury or death Apply the brakes gradually When driving downhill follow these precautions 1 Always move the 4X4 switch to ADC 4X4 before ascending or descending a hill See page 49 2 Always descend a hill with the transmission in forward gear Do not descend a hill with the transmission in neutral Slow down Proceed dire
113. splay in the LCD and the speedometer needle will blink Refuel immediately 8 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 ATV if this warning appears Serious engine damage could result 9 Mode Indicator 53 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 38 NOTE The transmission cannot be in reverse when using this feature Odometer Mode The odometer records the miles traveled by the ATV Trip Meter Mode The trip meter records the miles traveled by the ATV 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 NOTE Inthe Rider Information Center the trip meter display contains a deci mal 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 NOTE Small fluctuations in the RPM from day to day may be normal because of changes in humidity temperature and elevation Clock Mode The clock displays time in a 12 hour format To reset the clock see page 55 54 FEAT
114. ss of control or an accident HOW TO AVOID THE HAZARD Never exceed the stated load capacity for this ATV Cargo should be properly distributed and securely attached Reduce speed when carrying cargo or pulling a trailer Allow a greater distance for braking Always follow the instructions in the owner s manual for carrying cargo or pulling a trailer See page 64 Always follow the instructions in the owner s manual for operating with a passenger See page 70 A WARNING POTENTIAL HAZARD Operating on frozen bodies of water WHAT CAN HAPPEN Severe injury or death can result if the ATV and or riders fall through the ice HOW TO AVOID THE HAZARD Never operate the ATV on a frozen body of water 36 SAFETY Rider Safety A WARNING Operating a damaged ATV can result in an accident with serious injury or death After any overturn or accident have a qualified service dealer inspect the entire machine for possible damage including but not limited to brakes throttle and steering systems A WARNING Safe operation of this rider active vehicle requires good judgement and physical skills Persons with cognitive or physical disabilities who operate this vehicle have an increased risk of overturn and loss of control which could result in severe injury or death Never secure a passenger to the vehicle or to the operator with a belt rope or similar device A WARNING Exhaust
115. system components are very hot during and after use of the vehicle Hot components can cause serious burns and fire Do not touch hot exhaust system components Always keep combustible materials away from the exhaust system Use caution when traveling through tall grass especially dry grass A WARNING Leaving the keys in the ignition can lead to unauthorized use of the vehicle resulting in serious injury or death Always remove the ignition key when the vehicle is not in use 37 FEATURES AND CONTROLS Switches Worklight Headlight Switch Differential Switch fequipped pa er Switch p iS zi i Switch Mode Reverse Override Engine Main Key Switch Switch Stop Switch A WARNING Activating the override switch while the throttle is open can cause loss of control resulting in severe injury or death Do not activate the override switch while the throttle is open Mode Reverse Override Switch This vehicle is equipped with a reverse speed limiter system To gain additional power while backing depress the override switch NOTE The override switch also allows activation of 4X4 in reverse if the 4X4 Switch is on This switch is also used to toggle through the modes of the rider information center See page 52 Engine Stop Switch Move the stop switch either left or right to ar T LJ the OFF position to stop the engine quickly The engine will not start or run when the OFF
116. t the handling of the ATV and could result in loss of control accident and or injury HOW TO AVOID THE HAZARD Avoid operating the ATV on pavement If it s unavoidable travel slowly and avoid sudden turns or stops 23 SAFETY Rider Safety A WARNING POTENTIAL HAZARD Operating this ATV on public streets roads or highways WHAT CAN HAPPEN The ATV could collide with another vehicle HOW TO AVOID THE HAZARD Never operate the ATV on any public street road or highway including dirt and gravel roads In many states it s illegal to operate ATVs on public streets roads and highways A WARNING POTENTIAL HAZARD Riding an ATV without wearing an approved helmet eye protection and protective clothing WHAT CAN HAPPEN Riding an ATV without an approved helmet increases the risk of a severe head injury or death in the event of an accident Riding without eye protection could result in an accident and could increase the chance of a severe injury in the event of an accident HOW TO AVOID THE HAZARD Always be sure operator and passenger wear an approved helmet that fits properly A passenger s helmet should have a rigid chin guard Always be sure operator and passenger wear eye protection goggles or face shield gloves boots a long sleeved shirt or jacket and long pants 24 SAFETY Rider Safety A WARNING POTENTIAL HAZARD Operating the ATV after consuming al
117. tank or any other part of the machine when turned fully to the left or right 4 Torque the front two bolts to 10 12 ft Ibs 14 17 Nm then Handlebar torque the rear two bolts A Bolts gap of up to 1 8 3 mm will remain at the rear of the clamp blocks 137 ADJUSTMENTS Throttle Body Idle RPM Idle RPM is preset by the manufacturer If the engine idle speed is not satisfactory please see your Polaris dealer for adjustment Throttle Cable Freeplay Adjust throttle cable freeplay at the handlebar 1 Locate the throttle cable adjuster at the handlebar 2 Squeeze the end of the rub a ber boot and slide it far Ji enough to expose the end of the inline cable adjuster 3 Loosen the adjuster lock nut Rotate the boot to turn the adjuster until 1 16 to 1 8 1 5 3 mm of freeplay is achieved at the thumb lever NOTE While adjusting freeplay be sure to flip the throttle lever back and forth 5 Tighten the lock nut Boot 6 Squeeze the end of the rub ber boot and slide it over the cable adjuster to its original position Lock Nut Adjuster 138 TROUBLESHOOTING Drive Belt Wear Burn Possible Cause Driving onto a pickup or tall trailer in high range Solution Use low range during loading Starting out going up a steep incline Use low range or turn around using the K turn see page 76 Driving at low RPM or ground speed 3 7 MPH Drive at a higher speed or use low range
118. tarting the engine Also check occasionally during operation Engine speed and vehicle move ment are controlled by pressing the throttle lever The throttle lever is spring loaded Engine speed returns TI to idle when the lever is released f xj Tus ATV is equipped with Polaris 4 gt ectronic Throttle Control ETC Fest which is designed to reduce the risk of a frozen or stuck throttle If the throttle cable should stick in an open position when the operator releases the throttle lever the engine will stop and power to the rear wheels will cease A WARNING Modifications to the ETC could result in failure to perform as designed which could result in severe injury or death Do not attempt to modify the ETC system or replace it with any after market throttle mechanisms Always ensure that the throttle cable is properly installed to the ETC 40 FEATURES AND CONTROLS Brake Lever Squeeze the brake lever toward the handlebar to apply the front and rear brakes These brakes are hydraulically activated disc type brakes that are activated by only one lever Always test brake lever travel and master cylinder fluid level before riding When squeezed the lever should feel firm Any sponginess would indicate a possible fluid leak or low master cylinder fluid level which must be corrected before riding Contact your dealer for proper diagnosis and repairs A WARNING
119. tenance Interval Remarks whichever comes first Hours Calendar Miles Km Valve clearance 100 H 12M 1000 1600 Inspect adjust Fuel system 100 H 12M 1000 1600 Check for leaks at tank cap lines filter pump replace lines every two years gt Radiator 100 H 12M 1000 1600 Inspect clean external if applicable surfaces gt Cooling hoses 100 H 12M 1000 1600 Inspect for leaks if applicable gt Engine mounts 100 H 12M 1000 1600 Inspect Exhaust muffler 100 H 12M 1000 1600 Inspect pipe E Spark plug 100 H 12M 1000 1600 Inspect replace as needed gt Wiring 100 H 12M 1000 1600 Inspect for wear routing security apply dielectric grease to connectors subjected to water mud etc W Clutches drive 100 H 12M 1000 1600 Inspect clean replace worn and driven parts E Front wheel 100 H 12M 1000 1600 Inspect replace as needed bearings E Brake fluid 200 H 24M 2000 3200 Change every two years E ADC fluid 200 H 24M 2000 3200 Change every two years ADC models gt Fuel filter 200 H 24M 2000 3200 Check for leaks around lines a Replace every 2 years more E often under extreme conditions Spark arrestor 300 H 36M 3000 4800 Clean out E Toe adjustment Inspect 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 W Have an authorized Polaris deal
120. that could cause a fall from the vehicle or vehicle tipover A WARNING POTENTIAL HAZARD Skidding or sliding WHAT CAN HAPPEN Skidding or sliding can cause loss of control If the tires regain traction unexpectedly the ATV could overturn HOW TO AVOID THE HAZARD On slippery surfaces such as ice travel slowly and use extra caution to reduce the chance of skidding or sliding out of control 33 SAFETY Rider Safety A WARNING POTENTIAL HAZARD Operating the ATV through deep or fast flowing water WHAT CAN HAPPEN Tires may float causing loss of traction and loss of control which could lead to an accident or overturn HOW TO AVOID THE HAZARD Avoid operating the ATV through deep or fast flowing water If it s unavoidable to enter water that exceeds the recommended maximum depth see page 78 travel slowly balance your weight carefully avoid sudden movements and maintain a slow and steady forward motion Do not make sudden turns or stops and do not make sudden throttle changes Wet brakes may have reduced stopping ability Always test the brakes after leaving water If necessary apply them several times to let friction dry out the pads A WARNING POTENTIAL HAZARD Improperly operating in reverse WHAT CAN HAPPEN The ATV could collide with an obstacle or person resulting in severe injury HOW TO AVOID THE HAZARD Before shifting into reverse gear always
121. that this spark arrestor be installed and functional when the vehicle is operated on public lands Operation of off road vehicles on public lands in the U S A is regulated by 43 CFR 8343 Violations are subject to monetary penalties Federal regulations can be viewed online at www gpoaccess gov ecfr Crankcase Emission Control System This engine is equipped with a closed crankcase system Blow by gases are forced back to the combustion chamber by the intake system AII exhaust gases exit through the exhaust system Exhaust Emission Control System Exhaust emissions are controlled by engine design An electronic fuel injection EFI system controls fuel delivery The engine and EFI com ponents are set at the factory for optimal performance and are not adjustable The emissions label is located on the battery box Electromagnetic Interference This spark ignition system complies with Canadian ICES 002 This vehicle complies with European directives 97 24 EC and 89 336 EEC 84 MAINTENANCE Periodic Maintenance Chart Careful periodic maintenance will help keep your vehicle in the safest most reliable condition Inspection adjustment and lubrication of important components are explained in the periodic maintenance chart Inspect clean lubricate adjust and replace parts as necessary When inspection reveals the need for replacement parts use genuine Polaris parts available from your Polaris dealer Record maintenance and servic
122. the dealer photo identification from the country of the selling dealer s authorized location as proof of residence Upon residence verification the servicing dealer will be authorized to per form the warranty repair If You Move If you move to another country be sure to contact Polaris Customer Assistance and the customs department of the destination country before you move Vehicles importation rules vary considerably from country to country You may be required to present docu mentation of your move to Polaris Industries in order to continue your warranty cover age You may also be required to obtain documentation from Polaris Industries in order to register your vehicle in your new country 153 WARRANTY Exported Vehicles How to Get Service If Purchased From A Private Party If you purchase a Polaris product from a private citizen outside of the country in which the vehicle was originally purchased all warranty coverage will be denied Notice If your vehicle is registered outside of the country where it was purchased and you have not followed the procedure set out above your vehicle will no longer be eligible for war ranty or service bulletin coverage of any kind Vehicles registered to Government offi cials or military personnel on assignment outside of the country where the vehicle was purchased will continue to be covered by the basic warranty For questions call Polaris Customer Assistance United States 1 888 704
123. the system to be out of balance creating vibration and additional loads on components The PVT system rotates at high speeds creating large amounts of force on clutch components Extensive engineering and testing has been conducted to ensure the safety of this product However as the owner you have the following responsibilities to make sure this system remains safe Always follow all recommended maintenance procedures See your dealer as outlined in the owner s manual This PVT system is intended for use on Polaris products only Do not install it in any other product Always make sure the PVT housing is securely in place during operation 120 MAINTENANCE PVT System The basic operation of the Polaris PVT system is dependent on engine speed and vehicle torque requirements As engine speed increases the force exerted on the movable drive sheave by the flyweights also increases This in turn increases the amount of pinch applied to the drive belt Similarly if the engine speed decreases the amount of cen trifugal force decreases reducing the amount of belt pinch On Polaris ATVs the approximate gear ratio difference between high and low range is 1 2 25 This difference in gearing affects the operation of the PVT especially at speeds less than 7 MPH 11 km h due to the system s dependence on engine speed For example when operating at a ground speed of 3 MPH 5 km h in low range the engine speed would be
124. tion and operate in ADC 4X4 or 4X4 on these types of terrain Worklight Switch Use the worklight switch if equipped to turn the worklight on or off The worklight is located at the rear of the vehicle Turn the light on while loading and unloading cargo in low light situations Turn the worklight off when driving Headlight Switch Use the headlight switch to turn the lights on and off and to change the lights from high beam to low beam The key must be in the ON position and the engine stop switch must be in the RUN position A WARNING Operating the ATV on streets or roads especially in darkness could result in an accident and serious injury or death Your ATV is not equipped with highway approved lights It s designed for and must be used for off road use only Use caution and drive at reduced speeds in conditions of reduced visibility such as fog rain and darkness 39 FEATURES AND CONTROLS Throttle Lever A WARNING Operating an ATV with sticking or improperly operating throttle controls could cause an accident and lead to severe injury or death Never start or operate an ATV with a sticking or improperly operating throttle Always contact your dealer for service if throttle problems arise Failure to check or maintain proper operation of the throttle system can result in an accident if the throttle lever sticks during operation Always check the lever for free movement and return before s
125. tions to the vehicle for these purposes Any modifications to the original equipment of the vehicle create a substantial safety hazard and increase the risk of bodily injury The warranty on your Polaris ATV is terminated if any equipment has been added to the vehicle or if any modifications have been made to the vehicle that increase its speed or power NOTE The addition of certain accessories including but not limited to mow ers blades tires sprayers or large racks may change the handling characteristics of the vehicle Use only Polaris approved accessories and familiarize yourself with their function and effect on the vehicle 21 SAFETY Rider Safety A WARNING POTENTIAL HAZARD Operating this ATV without proper instruction WHAT CAN HAPPEN The risk of an accident is greatly increased if the operator does not know how to operate the ATV aoe properly in different situations and on different types of terrain HOW TO AVOID THE HAZARD Beginning and inexperienced operators should complete the ATV RiderCourse offered by Polaris through the SVIA They should then regularly practice the skills learned in the course and the operating techniques described in the Owner s Manual For more information about the ATV RiderCourse contact ATV Enrollment Express at 800 887 2887 or visit www atvsafety org A WARNING POTENTIAL HAZARD Failure to follow the age recommendations for this ATV WHAT CAN HAP
126. to cool before removing the pressure cap 1 Open the front box cover and pull open the access door 2 Remove the pressure cap 3 Using a funnel slowly add coolant through the radiator filler neck 4 Reinstall the pressure cap 5 Secure the access door 6 Secure the box cover NOTE Use of a non standard pressure cap will not allow the recovery system to function properly Contact your dealer for the correct replacement part Radiator Cap 103 MAINTENANCE Brakes Hand Brake The front and rear brakes are hydraulic disc brakes activated by moving the single brake lever toward the handlebar These brakes are self adjusting Under normal operation the diaphragm extends into the reservoir as fluid level drops If the fluid level is low and the diaphragm is not extended a leak is likely and the diaphragm should be replaced To ensure proper diaphragm operation always fill the reservoir as needed whenever the cover is loosened or removed Do not overfill A WARNING An over full master cylinder may cause brake drag or brake lock up which could result in serious injury or death Maintain brake fluid at the recommended level Do not overfill The following checks are recommended to keep the brake system in good operating condition Check more often if brakes are used heavily under normal operation 1 Always keep brake fluid at an adequate level See page 42 Check the brake syst
127. top if uncomfortable get off and walk if conditions require 7174028 SAFETY Safety Decals and Locations Tire Pressure Load Warning WARNING IMPROPER TIRE PRESSURE OR VERLOADING can cause loss of control resulting in SEVERE INJURY Tire Pressure Load OR DEATH Warning TIRE PRESSURE IN PSI KPa FRONT 5 34 5 REAR 5 34 5 MAXIMUM WEIGHT CAPACITY 705 LBS 820 kg INCLUDES WEIGHT OF A E OPERATOR PASSENGER CR CARGO AND ACCESSORIES SSN Reduce speed and allow greater distance for braking when carrying cargo Overloading or carrying tall off center or unsecured loads will increase your risk of losing control Loads should be centered carried as low as possible in box and firmly secured to the box For stability on rough or hilly terrain reduce speed and cargo Do not block headlight Be careful if load extends over the side of the rack or box Read Owner s Manual for more detailed loading information 7174885 SAFETY Safety Decals and Locations Rack Box Warning Warning Clutch Cover Warning Rack Warning Front WARNING DO NOT TOW FROM RACK OR BUMPER Vehicle damage or tipover may result causing severe injury or death Tow only from tow hooks or hitch Maximum combined Front Rack and Container Load 90 Ibs 41 kg 7174201 Clutch Cover Warning WARNING NO STEP Moving parts hazard under belt clutch guard To prevent serious injury do not operate vehicle with guard remove
128. with fresh ADC fluid 5 Remove the protective caps from the bleeder valves 6 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 7 Torque the valves to 80 in Ibs 9 Nm Reinstall the valve caps 8 Add fresh ADC fluid to the reservoir until the level is between the minimum and maximum marks Make sure the reservoir is free of debris 9 Reinstall the cap securely Clean up any drips or spills 101 MAINTENANCE Cooling System The engine coolant level is controlled or maintained by the recovery system The recovery system components are the recovery bottle the radiator filler neck the radiator pressure cap and the connecting hose As coolant operating temperature increases the expanding heated excess coolant is forced out of the engine past the pressure cap and into the recovery bottle As engine coolant temperature decreases the con tracting cooled coolant is drawn back up from the bottle past the pres sure cap and into the radiator NOTE Some coolant level drop on new vehicles is norm
129. ys follow the inspection and maintenance procedures and schedules described in the owner s manual 26 SAFETY Rider Safety A WARNING POTENTIAL HAZARD Removing hands from the handlebars or feet from the footrests during operation WHAT CAN HAPPEN Removing even one hand or foot can reduce ability to control the vehicle or could cause loss of balance and ejection from the ATV If a person s feet are not firmly planted on the footrests they could come into contact with the wheels or other moving parts and lead to accident or injury HOW TO AVOID THE HAZARD Always keep both hands on the handlebars and both feet on the footrests of the ATV during operation A passenger should always be seated in the passenger seat with both feet on the footrests and both hands on the passenger grab handles at all times The passenger should never hold on to the operator A WARNING POTENTIAL HAZARD Failure to use extra caution when operating the ATV on unfamiliar terrain WHAT CAN HAPPEN Unfamiliar terrain may contain hidden rocks bumps or holes that could cause loss of control or overturn HOW TO AVOID THE HAZARD Travel slowly and use extra caution when operating on unfamiliar terrain Always be alert to changing terrain conditions 27 SAFETY Rider Safety A WARNING POTENTIAL HAZARD Failure to use extra caution when operating on excessively rough slippery or loose t

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