MAINTENANCE

PERIODIC MAINTENANCE

Any qualified repair shop or person may maintain, replace or repair the emission control devices or systems on your vehicle. An authorized POLARIS dealer can perform any service that may be necessary for your vehicle. POLARIS also recommends POLARIS parts for emissions-related service, however equivalent parts can be used.

It is a potential violation of the Clean Air Act if a part supplied by an aftermarket parts manufacturer reduces the effectiveness of the vehicle’s emission controls. Tampering with emission controls is prohibited by federal law.

Owners are responsible for performing the scheduled maintenance identified in this owner’s manual. Careful periodic maintenance will help keep your vehicle in safe, reliable condition. Inspect, clean, lubricate, adjust and replace parts as necessary. When inspection reveals the need for replacement parts, genuine POLARIS parts are available from your POLARIS dealer. Equivalent parts may be used for emissions-related service.

Record maintenance and service in the Maintenance Log beginning on page

181. Service and adjustments are important for proper vehicle operation. If you’re not familiar with safe service and adjustment procedures, a qualified dealer can perform these operations. Maintenance intervals in the following chart are based upon average riding conditions and an average vehicle speed of approximately 10 mph (16 km/h). Vehicles subjected to severe use must be inspected and serviced more frequently.

SEVERE USE DEFINITION

• Frequent immersion in mud, water or sand
• Frequent or prolonged operation in dusty environments
• Short trip cold weather operation
• Racing or race-style high RPM use
• Prolonged low speed, heavy load operation
• Extended idle

Pay special attention to the oil level. A rise in oil level during cold weather can indicate contaminants collecting in the oil sump or crankcase. Change oil immediately if the oil level begins to rise. Monitor the oil level, and if it continues to rise, discontinue use and determine the cause. Your dealer can assist.

POLARIS MAINTENANCE SCHEDULE

The intervals shown are based on vehicles operated under normal conditions.

Each interval is given in hours and miles (kilometers). Items should be serviced at whichever interval comes first.

Continue to reference the following maintenance schedules at the given intervals as hours and miles (kilometers) increase on the vehicle.

Vehicles subjected to severe use must be serviced at 50% of the stated interval. Examples of Severe Use: Frequent immersion in mud, water, or sand, constant high RPM use, prolonged low-speed heavy load operation, extended idle, and short trip cold weather operation.

INITIAL BREAK-IN SERVICE FIRST 25 HOURS / 250 MILES (400 KM)

Brake System	Initial fluid level inspection; inspect for fluid leaks; add recommended brake fluid from a sealed container if needed. Inspect brake pad wear.
Engine Oil and Filter	Change the engine oil and filter.
Front / Rear Gearcase Fluid	Change fluid.
Transmission Fluid	Break in fluid change.
The break-in period consists of the first 25 hours of operation. Careful treatment of a new engine and drive components will result in more efficient performance and longer life for these components. The items outlined in this service interval only need to be performed at the first 25 hours of operation. They do not need to be performed every 25 hours.

Vehicles subjected to severe use must be serviced at 50% of the stated interval. Examples of Severe Use: Frequent immersion in mud, water, or sand, constant high RPM use, prolonged low-speed heavy load operation, extended idle, and short trip cold weather operation.

EVERY 50 HOURS / 500 MILES (800 KM)

Brake Pad Wear**	Inspect; replace as needed.
General Lubrication	Locate all applicable fittings and grease.
**Vehicles subjected to consistent mud conditions should be inspected and replaced as needed every 8 hours / 25 miles (40 km) of use. Mud Edition models equipped with HD brake pads should be inspected and replaced as needed every 24 hours / 100 miles (161 km) of use.

Vehicles subjected to severe use must be serviced at 50% of the stated interval. Examples of Severe Use: Frequent immersion in mud, water, or sand, constant high RPM use, prolonged low-speed heavy load operation, extended idle, and short trip cold weather operation.

EVERY 100 HOURS / 1000 MILES (1600 KM) OR YEARLY

Air Filter	Replace air filter. Ensure proper installation of filter and airbox cover. Inspect ducts and screens; clean as necessary.
Battery	Check terminals; terminals should be tight and free of corrosion. Clean, test, and replace as necessary.
Body to Frame Fasteners	Inspect; tighten as needed.
Brake Pad Wear**	Inspect; replace as needed.
Clutches*	Inspect bushings, rollers, wearable parts; clean; replace worn parts.
Cooling System	Fluid level inspection; inspect for fluid leaks; add coolant if needed. Inspect coolant strength seasonally; pressure test system yearly.
Drive Belt	Inspect; replace as needed.
Engine Breather	Inspect; clean; replace if necessary.
Engine Oil and Filter	Change the engine oil and filter.
Exhaust Silencer / Pipe	Inspect for leaks or damage.
Front / Rear Gearcase Fluid	Check fluid.
Front / Rear Suspension	Lubricate (if applicable).
Fuel System*	Cycle key to pressurize fuel pump; check for leaks at fuel system connections, check for leaks at fill cap.
General Lubrication	Locate all applicable fittings and grease.
Temporary Brake Lock	Inspect.
Spark Arrestor	Clean out.
Spark Plugs	Inspect; replace as needed.

EVERY 100 HOURS / 1000 MILES (1600 KM) OR YEARLY

Suspension Components*	Inspect tie rods, wheel bearings, suspension bushings, and ball joints for loose or worn components; replace as needed. Inspect shock absorbers for leaks or damage.
Throttle Cable (if applicable)*	Inspect; adjust; replace if necessary.
Transmission Fluid	Check fluid.
Wiring	Inspect for wear, routing, and retention.
* Have an authorized Polaris dealer or other qualified person perform these services. **Vehicles subjected to consistent mud conditions should be inspected and replaced as needed every 8 hours / 25 miles (40 km) of use. Mud Edition models equipped with HD brake pads should be inspected and replaced as needed every 24 hours / 100 miles (161 km) of use.

Vehicles subjected to severe use must be serviced at 50% of the stated interval. Examples of Severe Use: Frequent immersion in mud, water, or sand, constant high RPM use, prolonged low-speed heavy load operation, extended idle, and short trip cold weather operation.

ADDITIONAL MAINTENANCE INTERVALS

Every 200 hours / 2000 miles (3200 km)	Front / Rear Gearcase Fluid	Change fluid.
	Transmission Fluid	Change fluid.
Every 250 hours / 2500 miles (4000 km)	Shock Absorbers*	Replace or rebuild (if applicable).
Every 500 hours / 5000 miles (8000 km)	Valve Clearance*	Inspect; adjust as needed.
Every 24 months / 2 years	Brake Fluid	Change fluid.
Every 60 months / 5 years	Coolant	Change fluid.
* Have an authorized Polaris dealer or other qualified person perform these services.

LUBRICATION GUIDE

Check and lubricate all components at the intervals outlined in the Maintenance Interval Chart. Items not listed in the chart should be lubricated at the General Lubrication interval.

The a-arms and lower control arms are lubricated at the factory, and no additional lubrication will be needed.

ITEM	RECOM- MENDED LUBRICANT	CAPACITY AT FLUID CHANGE	FILL PLUG TORQUE	DRAIN PLUG TORQUE	SEE PAGE
Engine Oil	PS-4 5W-50 4-Cycle Oil	2 qt (1.9 L)	—	12 ft-lbs (16 N·m)	page 100
Transmission Fluid	AGL Gearcase Lubricant & Transmission Fluid	37 oz (1100 mL)	12 ft-lbs (16 N·m)	12 ft-lbs (16 N·m)	page 104
Front Gearcase Fluid	Demand Drive Fluid	9.3 oz (275 mL)	19 ft-lbs (26 N·m)	19 ft-lbs (26 N·m)	page 106
Rear Gearcase Fluid	Angle Drive Fluid (or GL5 80- 90 weight gear lube)	7.1 oz (210 mL)	12 ft-lbs (16 N·m)	12 ft-lbs (16 N·m)	page 108
Brake Fluid	DOT 4 Brake Fluid	—	—	—	page 41
Front Prop Shaft Yoke	U-Joint Grease	Grease fittings (3 pumps maximum) every 500 miles (800 km), before long periods of storage, or after pressure washing or submerging.

ENGINE OIL

Vehicle operation with insufficient, deteriorated, or contaminated engine oil will cause accelerated wear and may result in engine seizure, accident and injury.

WARNING

Always check and change the engine oil at the intervals outlined in the Maintenance Interval Chart. Always use the recommended engine oil.

Pay special attention to the oil level. A rise in oil level during cold weather can indicate contaminants collecting in the oil sump or crankcase. Change oil immediately if the oil level begins to rise. Monitor the oil level, and if it continues to rise, discontinue use and determine the cause. Your authorized dealer can assist.

OIL RECOMMENDATIONS

Always change the oil filter when you change the engine oil.

IMPORTANT

POLARIS recommends the use of POLARIS PS-4 Full Synthetic 5W-50 4-cycle oil or a similar oil for this engine. Oil may need to be changed more frequently if POLARIS oil is not used. Always use 5W-50 oil. Follow the manufacturer’s recommendations for ambient temperature operation.

See the Lubrication Guide section for fluid recommendations, capacities, and plug torques.

Mixing brands or using a non-recommended oil may cause serious engine damage. Always use the recommended oil. Never substitute or mix oil brands.

IMPORTANT

OIL LEVEL CHECK

Check the oil level when the engine is cold. Never check the oil with the engine running or damage to the dipstick and / or engine could occur.

IMPORTANT

To check the oil level, do the following:

1. Position the vehicle on a level surface.
2. Access the oil dipstick and fill tube from the left side of the ATV q. Remove the dipstick. Wipe it dry with a clean cloth.
3. Reinstall and tighten the dipstick.
4. Remove the dipstick and check the oil level.
5. Add the recommended fluid as needed. Maintain the oil level in the safe range between the FULL and ADD marks. Do NOT overfill.
6. Reinstall and tighten the dipstick.

OIL AND OIL FILTER CHANGE

Always change the oil filter when you change the engine oil.

IMPORTANT

The engine oil and oil filter should be changed in accordance with the Maintenance Interval Chart. See the Lubrication Guide section for fluid recommendations, capacities, and plug torques.

1. Position the vehicle on a level surface.
2. Clean the area around the drain plug.
3. Place a drain pan under the crankcase.
4. Remove the drain plug. Allow the oil to drain completely.

Hot oil can cause burns to skin. Do not allow hot oil to contact skin.

CAUTION

1. Install a new sealing washer on the drain plug. The sealing surfaces on drain plug and crankcase should be clean and free of burrs, nicks or scratches.
2. Reinstall the drain plug. Torque to specification.

Drain Plug:

12 ft-lbs (16 N·m)

TORQUE

1. Remove the oil filter cover plate by loosening the three screws holding into place.
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.
3. Using a clean dry cloth, clean the filter sealing surface on the crankcase.
4. 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.
5. 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.
6. Replace the oil filter plate. Torque screws to specification.

Oil Filter Plate Screws

7 ft-lbs (9 N·m)

TORQUE

1. Remove the dipstick. Add the proper amount of the recommended oil. Do not overfill.
2. Reinstall the dipstick.
3. Place the transmission in PARK.
4. Lock the temporary brake lock.
5. Start the engine. Allow it to idle for one to two minutes.
6. Stop the engine.
7. Check for leaks.
8. Check the oil level. Add oil as needed to bring the level to the upper mark on the dipstick.
9. Dispose of used filter and oil properly.

TRANSMISSION FLUID

Always check and change the transmission fluid at the intervals outlined in the Maintenance Interval Chart. See the Lubrication Guide section for fluid recommendations, capacities, and plug torques.

Maintain the fluid level at the bottom of the fill plug hole q.

The fill plug is located on the right side of the ATV behind the footwell. The drain plug w is located on the bottom rear side of the gearcase.

FLUID CHECK

1. Remove the footwell.
2. Remove the fill plug. Check the fluid level.
3. Add the recommended fluid as needed to bring the level to the bottom of the fill hole threads.
4. Reinstall the fill plug. Torque to specification.

Fill Plug:

12 ft-lbs (16 N·m)

TORQUE

1. Reinstall the footwell.

FLUID CHANGE

1. Remove the footwell.
2. Place a drain pan under the gearcase. Remove the drain plug. Allow the fluid to drain completely.
3. Clean and reinstall the drain plug. Torque to specification.

Drain Plug:

12 ft-lbs (16 N·m)

TORQUE

1. Remove the fill plug. Add the proper amount of the recommended fluid.
2. Reinstall the fill plug. Torque to specification.

Fill Plug:

12 ft-lbs (16 N·m)

TORQUE

1. Check for leaks.
2. Reinstall the footwell.
3. Dispose of used fluid properly.

FRONT GEARCASE (DEMAND DRIVE) FLUID

Always check and change the demand drive fluid at the intervals outlined in the Maintenance Interval Chart.

Change the front gearcase fluid every 25 hours if the ADC unit is exposed to extreme use. Extreme use includes any of the following:

• Operation in ADC mode for prolonged periods.
• Constant ADC operation on hilly or mountainous terrain.
• ADC is the primary mode of all-wheel-drive operation.

If the front gearcase is making excessive noise during ADC operation, change the demand drive fluid. If the noise continues, please see your POLARIS dealer or other qualified service facility for service.

TIP

Use the recommended fluid. Use of other fluids may result in improper operation of components. Maintain the fluid level at the bottom of the fill hole threads. The fill plug is located on the right side of the demand drive unit. The drain plug is located on the bottom right side of the unit.

FLUID CHECK

1. Position the vehicle on a level surface. Remove the fill plug q. Check the fluid level.
2. Add the recommended fluid as needed to bring the level to the bottom of the fill hole threads.
3. Reinstall the fill plug. Torque to specification.

Fill Plug:

19 ft-lbs (26 N·m)

TORQUE

FLUID CHANGE

• 1. Position the vehicle on a level surface. Remove the fill plug q.
  2. Place a drain pan under the demand drive unit. Remove the drain plug w. Allow the fluid to drain completely.
  3. Clean and reinstall the drain plug. Torque to specification.

Drain Plug:

19 ft-lbs (26 N·m)

TORQUE

• 1. Add the recommended fluid as needed to bring the level to the bottom of the fill hole threads.
  2. Reinstall the fill plug. Torque to specification.

Fill Plug:

19 ft-lbs (26 N·m)

TORQUE

• 1. Check for leaks. Dispose of used fluid properly.

REAR GEARCASE FLUID

Always check and change the rear gearcase fluid at the intervals outlined in the Maintenance Interval Chart. See the Lubrication Guide section for fluid recommendations, capacities, and plug torques.

The fill plug is located on the rear of the gearcase. The drain plug is located on the bottom of the gearcase.

Maintain the fluid level at the bottom of the fill hole threads. Do not overfill.

FLUID CHECK

1. Position the vehicle on a level surface.
2. Remove the fill plug q. Check the fluid level.
3. Add the recommended fluid as needed to bring the level to the bottom of the fill hole threads. Do not overfill.
4. Reinstall the fill plug. Torque to specification.

Fill Plug:

12 ft-lbs (16 N·m)

TORQUE

FLUID CHANGE

• 1. Position the vehicle on a level surface.
  2. Place a drain pan under the drain hole w.
  3. Remove the drain plug. Allow the fluid to drain completely.
  4. Clean and reinstall the drain plug with a new sealing washer. Torque to specification.

Drain Plug:

12 ft-lbs (16 N·m)

TORQUE

• 1. Remove the fill plug. Add the proper amount of the recommended fluid. Do not overfill.
  2. Reinstall the fill plug. Torque to specification.

Fill Plug:

12 ft-lbs (16 N·m)

TORQUE

• 1. Check for leaks.
  2. Dispose of used fluid properly.

POWER STEERING UNIT (IF EQUIPPED)

If your model is equipped with power steering, frequently clean the areas around and on the power steering unit to allow proper cooling. Clean these areas e thoroughly.

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 authorized dealer or other qualified service facility before operating the vehicle.

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 contracting (cooled) coolant is drawn back up from the bottle, past the pressure cap, and into the radiator.

Some coolant level drop on new vehicles is normal as the system is purging itself of trapped air. Check the coolant level and maintain as recommended by adding coolant to the recovery bottle.

POLARIS recommends the use of POLARIS Antifreeze 50/50 Premix. This antifreeze is already premixed and ready to use. Do not dilute with water. See the Polaris Products section for the part numbers.

RECOVERY BOTTLE COOLANT

The recovery bottle fluid level can be viewed from inside the front right wheel well. Access the recovery bottle cap under the front box.

1. View the fluid level in the bottle.
2. If the level is low, remove the bottle cap and add coolant as needed. Maintain the coolant level between the minimum and maximum marks on the bottle (when the fluid is cool).
3. Reinstall the cap.
4. Close and secure the front box and cover.

RADIATOR COOLANT

To ensure that the coolant maintains its ability to protect the engine, we recommend that the system be completely drained every five (5) years and fresh Antifreeze 50/50 Premix added.

Any time the cooling system has been drained for maintenance or repair, replace the coolant with fresh Antifreeze 50/50 Premix. If the recovery bottle has run dry, check the level in the radiator. Add coolant as needed.

Escaping steam can cause burns. Never remove the pressure cap while the engine is warm or hot. Always allow the engine to cool before removing the pressure cap.

CAUTION

1. Access the pressure cap under the front box. See the Front Compartment section for details.
2. Remove the pressure cap.
3. Using a funnel, slowly add coolant through the radiator filler neck.
4. Reinstall the pressure cap. Use of a non-standard pressure cap will not allow the recovery system to function properly. Your POLARIS dealer can provide the correct replacement part.
5. Close and secure the front box and cover.

BRAKES

HAND BRAKE

Brake discs can become extremely hot after operation. Allow the discs to cool before performing maintenance to prevent risk of burns.

CAUTION

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. The diaphragm is inside, under the reservoir cap, integrated into the seal for the master cylinder. 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.

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.

WARNING

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 the Master Cylinder/Brake Fluid section for details.
2. Check the brake system for fluid leaks.
3. Check the brakes for excessive travel or spongy feel.
4. Check the friction pads for wear, damage and looseness. Replace brake pads when they are worn to .030” (0.762 mm).
5. Check the security and surface condition of the disc. Clean any grease using a recommended brake cleaner or alcohol. Do not use spray lubricants or other petroleum-based products. If you discover any damage (cracks, excessive corrosion, warping) see your dealer for service before operating.

AUXILIARY FOOT BRAKE

The hydraulic auxiliary brake system requires no adjustment. Check the brake fluid level frequently for the auxiliary brake system.

SEAT REMOVAL

• 1. Locate the seat removal latch in the center of the seat’s rear.
  2. Pull on the latch handle to disengage the seat from the vehicle’s frame.
  3. Remove the seat.

TIRES

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. Always follow all tire maintenance procedures as outlined in this manual and on the labels on the vehicle. Always use original equipment size and type when replacing tires.

WARNING

Refer to the specifications section for recommended tire type, size and pressure.

TIRE TREAD DEPTH

Always replace tires when tread depth is worn to 3 mm (1/8”) or less.

WHEEL REMOVAL

Do not service axle nuts that have a cotter pin installed. Your authorized dealer can assist.

WARNING

1. Stop the engine, place the transmission in PARK, and lock the temporary brake lock.
2. Loosen the wheel nuts slightly.
3. Elevate the side of the vehicle by placing a suitable stand under the foot rest frame.
4. Remove the wheel nuts.
5. Remove the wheel.

WHEEL INSTALLATION

1. Place the transmission in PARK.
2. Lock the temporary brake lock.
3. Place the wheel on the hub with the valve stem toward the outside and rotation arrows on the tire pointing toward forward rotation (if equipped).
4. Install the wheel nuts and finger-tighten them.
5. Lower the vehicle to the ground.
6. Torque the wheel nuts to specification.

Loose nuts could cause a tire to come off during operation, which could result in an accident or overturn. Always make sure that all nuts are torqued to specification.

WARNING

WHEEL NUT TORQUE SPECIFICATIONS

Check the wheel nut torques occasionally and when they’ve been loosened for service.

WHEEL TYPE	NUT TORQUE
All	120 ft-lbs (163 N·m)

TOE ALIGNMENT

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 or other qualified service facility.

WARNING

Use the following procedure to check the toe alignment of the vehicle. The recommended toe alignment is 1/4-1/2 inch (6-12 mm).

• 1. Position the vehicle on a level surface.
  2. Place the handlebars in a straight-ahead position.
  3. Tie a length of string between two stands. Position the stands so that the string is flush with the side of the rear tire. If available, you may use a long straight-edge instead of string.
  4. Measure the distance from the string to the rim at the front q and rear w of the front rim. The rear measurement should be 1/8–1/4 inch (3–6 mm) more than the front measurement on each side of the vehicle to obtain the recommended 1/4–1/2 inch (6–12 mm) toe out alignment.
  5. Repeat the measurement procedure on the other side of the vehicle.
  6. If you discover improper alignment, see your POLARIS dealer for service.

CAMBER AND CASTER

The camber and caster are non-adjustable.

AIR FILTER INSTALLATION

1. Remove the seat, the air box cover strap w, and the air box cover q.

1. Remove the filter e.
2. Remove the fabric type pre- filter r from the main filter t. Wash the pre-filter in soapy water, then rinse and let dry.

1. Reinstall the pre-filter over the main filter. Install a new main filter if needed.
2. Reinstall the filter into the air box.
3. Reinstall the air box cover, the air box cover strap, and the seat.

FUSE REPLACEMENT

If the engine stops or will not start, or if you experience other electrical failures, a fuse may need replacement. Locate and correct any short circuits that may have caused the blown fuse, then replace the fuse.

Spare fuses are provided in the fuse box.

1. Access the fuses under the front box.

1. Remove the fuse box cover.
2. Remove the suspect fuse from the fuse panel. If the fuse is blown, install a new fuse with the same amperage rating.
3. Reinstall the fuse box cover.
4. Close and secure the front box and cover.

LIGHTS

Poor lighting can result in reduced visibility when driving. Headlight and taillight lenses become dirty during normal operation. Clean headlights frequently and replace burned out headlamps promptly.

Always make sure lights are adjusted properly for best visibility.

CAUTION

HEADLIGHT LAMP REPLACEMENT

When servicing a halogen lamp, avoid touching the lamp with bare fingers. Oil from your skin leaves a residue, causing a hot spot that will shorten the life of the lamp. If fingers do touch a lamp, clean it with denatured alcohol.

Hot components can cause burns to skin. Allow lamps to cool before servicing.

CAUTION

1. Remove the four (4) headlight pod screws. Pull the pod cover forward.

1. Unplug the headlamp from the wiring harness. Be sure to pull on the connector, not on the wiring.

1. Turn the lamp counter-clockwise to remove it.
2. Install the new lamp. Make sure the tab on the lamp locates properly in the housing.
3. Reassemble the pod.

HIGH BEAM ADJUSTMENT

The headlight beam can be adjusted slightly upward or downward. Use the following procedure to make the adjustment.

1. Position the vehicle on a level surface with the headlight approximately 25 ft. (7.6 m) from a wall q. Place the transmission in PARK.
2. Measure the distance from the floor to the center of the headlight and make a mark on the wall at the same height.
3. Start the engine. Turn the headlight switch to high beam.
4. Observe the headlight aim on the wall. The most intense part of the headlight beam should be 2 in. (5 cm) below the mark on the wallw. Include rider weight on the seat when measuring.
5. The adjustment screw is located on the left side of the headlight pod. To adjust the beam, loosen the screw. Adjust the headlamp to the desired position, then tighten the screw.

LOW BEAM ADJUSTMENT

The low beam can be adjusted slightly upward or downward by rotating the adjustment screw, located on either side of the vehicle.

HEADLIGHT HOUSING REPLACEMENT

1. Remove the four (4) headlight pod screws.

1. Pull the pod cover forward.
2. Unplug the headlamp from the wiring harness.

1. Use a small screwdriver to remove the o-rings from the headlight mounting tabs.
2. Pull the headlight housing up from the bracket for removal.
3. Reverse the steps to install the new housing and reassemble the pod.

LOWER HEADLAMP REPLACEMENT

1. Turn the back of the headlight harness counter-clockwise and pull the harness assembly away from the headlight assembly.

1. Remove the headlamp and install the new headlamp.
2. Reinstall the harness assembly into the headlight assembly.

Take care to avoid touching the glass on the new headlight bulb. Fingerprints on the glass may result in premature failure.

NOTE

1. Turn the headlight harness clockwise to secure the headlamp.

TAILLIGHTS/BRAKE LIGHTS REPLACEMENT

Procedure to replace taillights:

TO REPLACE LEFT TAILLIGHT:

1. Remove the harness connector from the back of the light assembly.
2. Remove the 3 fasteners securing the light assembly and remove the light assembly.
3. Install the new light assembly and tighten the 3 fasteners to secure the light assembly.
4. Reinstall the harness connector. Test the light for proper operation

TO REPLACE RIGHT TAILLIGHT:

1. Remove the heat shield covering the light assembly.
2. Remove the harness connector from the back of the light assembly.
3. Remove the 3 fasteners securing the light assembly, and then remove the assembly.
4. Install the new light assembly, then re-affix and tighten the 3 fasteners.
5. Reinstall the harness connector.
6. Reinstall the heat shield.
7. Test the light for proper operation.

TO REPLACE CENTER TAILLIGHT:

1. Remove the rear rack and rear storage box.
2. Remove the harness connector from the back of the light assembly.
3. Remove the 4 fasteners securing the light assembly, and then remove the assembly.
4. Install the new light assembly, then re-affix and tighten the 4 fasteners.
5. Reinstall the harness connector.
6. Reinstall the rear rack and rear storage box.
7. Test the light for proper operation.

SPARK PLUGS

SPARK PLUG RECOMMENDATIONS

Refer to the specifications section for the recommended spark plug type and gap for your vehicle. Torque spark plugs to specification.

Using non-recommended spark plugs can result in serious engine damage.

Always use POLARIS-recommended spark plugs or their equivalent.

NOTICE

PLUG CONDITION	TORQUE SPECIFICATION
New Spark Plug	15 ft-lbs (20 N·m)
Previously Installed Spark Plug	15 ft-lbs (20 N·m)

SPARK PLUG INSPECTION

Spark plug condition is indicative of engine operation. Check the spark plug for the correct color.

A hot exhaust system and engine can cause burns. Wear protective gloves when removing a spark plug for inspection. Allow engine to cool before removing spark plug wire.

CAUTION

• 1. Allow engine to completely cool down before removing/installing spark plugs.
  2. Rotate the spark plug cap q 1/4 turn and pull it off the spark plug.
  3. Rotate the spark plug w

counter-clockwise to remove it.

• 1. Reverse the procedure for spark plug installation. Torque to specification.

NORMAL PLUG

The normal insulator tip is gray, tan or light brown. There will be few combustion deposits. The electrodes are not burned or eroded. This indicates the proper type and heat range for the engine and the service.

The tip should not be white. A white insulator tip indicates overheating, caused by use of an improper spark plug or lean air/fuel ratio.

WET FOULED PLUG

The wet fouled insulator tip is black. A damp oil film covers the firing end. There may be a carbon layer over the entire nose. Generally, the electrodes are not worn. General causes of fouling are excessive oil consumption, use of

non-recommended oil, or poor fuel quality.

VEHICLE IMMERSION

If your vehicle becomes immersed, major engine damage can result if the machine is not thoroughly inspected. Take the vehicle in for service before starting the engine. Your POLARIS dealer can provide this service.

If it’s impossible to take your ATV to a dealer before starting it, follow the steps outlined below.

1. Move the ATV to dry land or at the very least, to water below the footrests.
2. Check the air box. If water is present, dry the air box and replace the filter with a new filter. If equipped, remove the air box drain plug q to drain water. Reinstall the drain plug. Make sure the E-ring is on the drain plug and reinstall the drain plug.

Serious damage could occur if the air box drain plug is not reinstalled and tightened properly.

NOTICE

1. Remove the spark plugs.
2. Turn the engine over several times using the electric start.
3. Dry the spark plugs. Reinstall the plugs or install new plugs.
4. Attempt to start the engine. If necessary, repeat the drying procedure.

Serious damage can occur after immersion if fluids are not changed promptly.

Your authorized dealer can assist.

NOTICE

1. Take the vehicle in for service as soon as possible, whether you succeed in starting it or not. Your authorized dealer can provide the required service.
2. If water has been ingested into the PVT, follow the procedure in the PVT System section for drying out the PVT.

SPARK ARRESTER

Failure to heed the following warnings while servicing the spark arrester could result in serious injury or death.

• Never run the engine in an enclosed area. Exhaust contains poisonous carbon monoxide gas that can cause loss of consciousness or death in a very short time.
• Wear eye protection and leather work gloves.
• Do not perform clean-out immediately after the engine has been run, as the exhaust system becomes very hot. Serious burns could result from contact with the exhaust components. Allow components to cool sufficiently before proceeding.

Never operate without the spark arrester

WARNING

Periodically clean the spark arrester to remove accumulated carbon.

1. Place the transmission in PARK.
2. Remove the four arrester cap bolts and remove the cap.

1. Remove the arrester retaining bolt and nut.

1. Remove the arrester from the end of the muffler.

1. Use non-synthetic brush to clean the arrester screen. A synthetic brush may melt if the components are warm. If necessary, blow debris from the screen with compressed air.
2. Inspect the screen for wear and damage. Replace a worn or damaged screen.
3. Reinstall the arrester.
4. Torque the retainer bolt to specification.

Retainer Bolt:

10 ft-lbs (14 N·m)

TORQUE

1. Reinstall the arrester cap and bolts. Torque to specification.

Cap Bolts:

10 ft-lbs (14 N·m)

TORQUE

PVT SYSTEM

WARNING

Failure to comply with the instructions in this warning can result in severe injury or death.

Do not modify any component of the PVT system. Doing so may reduce its strength so that a failure may occur at a high speed. The PVT system has been precision balanced. Any modification will cause the system to be out of balance, creating vibration and additional loads on components.

The PVT system rotates at high speeds, creating large amounts of force on clutch components. Extensive engineering and testing has been conducted to ensure the safety of this product. However, as the owner, you have the following responsibilities to make sure this system remains safe:

• Always follow all recommended maintenance procedures. Always look for and remove debris inside and around the clutch and vent system when replacing the belt.
• See your POLARIS dealer, or other qualified person, for service and repair assistance.
• This PVT system is intended for use on POLARIS products only. Do not install it in any other product.
• Always make sure the PVT housing is securely in place during operation.

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 centrifugal 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 around 3000 RPM. This is well above the engagement speed of 1600 – 1800 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.

The air temperature in the clutch cover is substantially reduced by using low range while operating at low ground speeds. Reducing the temperature inside the clutch cover greatly extends the life of the PVT components (belt, cover, etc.).

WHEN TO USE LOW RANGE AND HIGH RANGE

CONDITION	RANGE TO USE
Operating at speeds less than 7 MPH (11 km/h)	Low
Towing heavy loads	Low
Operating in rough terrain (swamps, mountains, etc.)	Low
Operating at speeds greater than 7 MPH (11 km/h)	High

PVT DRYING

There may be some instances when water is accidently ingested into the PVT system. Use the following instructions to dry it out before operating.

1. Position the vehicle on a level surface.
2. Remove the drain plug q. Allow the water to drain completely. Reinstall the drain plug.

1. Start the engine. Place the transmission in PARK.
2. Apply varying throttle for 10-15 seconds to expel the moisture and air-dry the belt and clutches. Do not hold the throttle wide open for more than 5 seconds.
3. Allow the engine RPM to settle to idle speed, then shift the transmission to low range.
4. Test for belt slippage. If the belt slips, repeat the process. Your vehicle requires service as soon as possible, which your authorized dealer can provide.

DRIVE BELT REMOVAL

• 1. Position the vehicle on a level surface and place the transmission in PARK.
  2. Elevate and safely support the rear of the vehicle.
  3. Remove the left rear wheel from the vehicle.
  4. Remove the (4) bolts q retaining the lower LH frame support w and remove from the frame.
  5. Remove the (11) fasteners securing the outer PVT cover to the inner PVT cover.
  6. Using care, pull the outer PVT cover out the left rear wheel well.

Flexing the PVT outlet duct aids PVT cover removal.

NOTICE

• 1. Note the orientation of the drive belt so that it can be installed in the same direction.
  2. Insert the provided clutch tool between the slides and rotate the tool to spread the sheaves.

Spanner Wrench / Spreader: PN 2877408

Make sure the tool is square with the moveable sheave surface of the driven clutch.

NOTICE

• 1. Once the sheaves have been spread, walk the drive belt out of the driven clutch and drive clutch, and remove it from the vehicle.

DRIVE BELT INSTALLATION

Orient the belt as it was removed or orient the new belt so that you can read the text.

IMPORTANT

• • 1. Spread the sheaves and walk the drive belt on to the drive clutch and driven clutch.

Spanner Wrench / Spreader: PN 2877408

Make sure the tool is square with the moveable sheave surface of the driven clutch.

NOTICE

• • 1. Release the sheaves and rotate the driven clutch counter-clockwise to make sure the sheaves close against the belt.
    2. Make sure the clutch cover seal is secure in the outer PVT cover.
    3. Install outer PVT cover and secure with fasteners. Torque fasteners to specification.

Outer PVT Cover Fasteners:

30 in-lbs (3 N·m)

TORQUE

• • 1. Install the (4) bolts retaining the lower LH frame support to the frame. Torque bolts to specification.

Lower LH Frame Support Fasteners:

45 ft-lbs (60 N·m)

TORQUE

• • 1. Install the left rear wheel and torque wheel nuts to specification.

Wheel Lug Nuts:

120 ft-lbs (162 N·m)

TORQUE

• • 1. Start the engine and test the operation of the PVT system.
    2. Always break in the drive belt after a belt replacement. For drive belt break-in information, see the Operation chapter.

BATTERY

Improperly connecting or disconnecting battery cables can result in vehicle/battery damage, an explosion, or 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.

WARNING

Your ATV is equipped with a sealed battery, which requires little maintenance. POLARIS does not recommend using a conventional battery in this vehicle. The orientation of the battery could result in electrolyte leakage, which would shorten the life of the battery considerably.

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 terminals with dielectric grease or petroleum jelly.

BATTERY REMOVAL

• • • 1. Access the battery by opening the front storage rack lid.
      2. Remove the storage compartment underneath by rotating the two quarter-turn fasteners and lifting the storage compartment.
      3. Disconnect the black (negative) battery cable first.
      4. Disconnect the red (positive) battery cable last.
      5. Disconnect the battery hold-down strap.
      6. Lift the battery out of the ATV.

BATTERY INSTALLATION

Using a new battery that has not been fully charged can damage the battery and result in a shorter life. It can also hinder vehicle performance. Follow the instructions in the Battery Charging section before installing the battery.

An optional extreme use battery may be available for your model. If the performance of the factory-installed battery is inadequate due to operation in extreme cold or due to extended use of multiple electrical accessories, your authorized dealer can assist. Your dealer can provide any installation procedures that may differ for an extreme use battery.

1. Ensure that the battery is fully charged.
2. Place the battery in the battery holder.
3. Coat the terminals with dielectric grease or petroleum jelly.
4. Secure the battery hold-down strap.
5. Connect and tighten the red (positive) cable first.
6. Connect and tighten the black (negative) cable last.
7. Verify that cables are properly routed. Cables should be safely tucked away at the front and rear of the battery.
8. Close and secure the front box and cover.

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.

Image is for reference only. Your model might differ slightly.

NOTICE

POLARIS recommends maintaining battery charge by using a POLARIS battery trickle charger or by charging once a month using the battery charge port q.

The POLARIS offered battery trickle charger can be left connected during the

storage period, and will automatically charge the battery if the voltage drops below a pre-determined point. See the POLARIS Products chapter for the part number.

POLARIS recommends using a trickle charger that shuts off automatically when the battery is fully charged. If you are not using a trickle charger that automatically shuts when the battery is fully charged, make sure to monitor the battery charge level and disconnect the charger when the battery is fully charged.

IMPORTANT

When using a battery trickle charger, always place the charger on the ground, or on a suitable elevated surface. Never place the charger on the vehicle or let it hang from the battery charge port while plugged in.

CAUTION

BATTERY CHARGING

The following battery charging instructions apply only to the installation of a sealed battery. Read all instructions before proceeding with the installation of this battery.

The sealed battery is already filled with electrolyte and has been sealed and fully charged at the factory. Never pry the sealing strip off or add any other fluid to this battery.

The single most important thing about maintaining a sealed battery is to keep it fully charged. Since the battery is sealed and the sealing strip cannot be removed, you must use a voltmeter or multimeter to measure DC voltage.

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.

WARNING

For a refresh charge, follow all instructions carefully.

• 1. The battery should be disconnected from a load or charger for at least two hours before checking voltage. Check the battery voltage with a voltmeter or multimeter. A fully charged battery will register 12.6 V or higher.
  2. If the voltage is less than 12.6 volts, recharge the battery at 1.2 amps or less until battery voltage is 12.6 or greater.
  3. When using an automatic charger, refer to the charger manufacturer’s instructions for recharging. When using a constant current charger, use the following guidelines via the table below.

BATTERY CHARGING (SEALED BATTERY)

Always verify battery condition before and 1-2 hours after the end of charging.

STATE OF CHARGE	VOLTAGE	ACTION	CHARGE TIME (USING CONSTANT CURRENT CHARGER @ STANDARD AMPS SPECIFIED ON TOP OF BATTERY)
100%	12.6-12.8 volts	Conventional/Low Maintenance Battery: check after 60 days AGM Battery: check after 30 days	None required
50%-75%	12.0-12.5 volts	Needs charge	5-11 hours
25%-50%	11.5-12.0 volts	Needs charge	At least 13 hours, verify state of charge
0%-25%	11.5 volts or less	AGM ONLY: needs charge with desulfating charger	At least 20 hours

BATTERY IDENTIFICATION

It is important to identify the type of battery installed in the vehicle. Different types of batteries require different service procedures. Proper servicing and upkeep of the battery is very important for maintaining long battery life. All Polaris ORV models include either a Conventional battery or a Low Maintenance battery.

IMPORTANT

CONVENTIONAL BATTERY

• The battery is NOT activated when packaged
• Distilled water and electrolyte added as required
• Removable cap plugs located on top of battery
• Vent tube located on side of battery

LOW MAINTENANCE BATTERY

• • Battery activated when packaged
  • Distilled water and electrolyte NEVER added
  • Non removable cap(s) located on top of battery

LEAD ACID CONVENTIONAL / DRY SHIPPED AGM BATTERY BEST PRACTICES

Some Polaris ORV models include either a Lead Acid Conventional battery or a Dry Shipped Absorbed Glass Mat (AGM) battery. See the Service Manual for procedures on how to activate, charge, maintain, and test a Lead Acid Conventional or Dry Shipped AGM battery.

Using a new battery that has not been fully charged can damage the battery and result in a shorter life. It can also hinder vehicle performance.

NOTICE

LEAD ACID CONVENTIONAL BATTERIES

ACTIVATION

A Polaris battery purchased from a Polaris dealership should be activated at time of purchase by the dealer.

NOTE

• • Do NOT activate the battery unless it will be put into regular service within 30 days. Bulk acid should be used to activate the battery.
  • Always remove the sealing cap from the vent elbow before activating the battery. Never put the sealing cap back onto the battery. The gas pressure can cause the battery to rupture.
• Let the battery sit for 30 minutes after you add the initial electrolyte. Once absorbed, fill the battery with additional electrolyte to the upper line of the electrolyte level indicator. This is the only time that electrolyte should be added to the battery.
• Once the battery is fully charged, replace cap plugs by hand. Do NOT use a tool to install the cap plugs.

CHARGING

• The battery must be fully charged before use or battery life will be significantly reduced by 10-30% of the battery’s full potential.
• Nominal voltage is 12.6 to 12.8 Volts when fully charged. If the voltage falls below 12.5V, charge it immediately, or the battery service life and vehicle performance may be affected.
• Polaris recommends using a BatteryMINDer® 12V 1.5 AMP Convertible (PN 2830511) charger (or a similar charger), which can be ordered through your normal parts channel.
• Charge the battery with a charging output no larger than 10% of the battery’s amp-hour rating.

MAINTENANCE

• Recharge the battery to its full capacity every 30 to 60 days.
• If the battery is stored or used in a partially charged condition, battery service life and vehicle performance may be adversely affected.
• Never add any electrolyte to the battery once the battery is in service. After the battery is initially activated, only distilled water should be added to maintain electrolyte levels.
• Store the battery in the vehicle with the cables disconnected, or store the battery in a cool / dry location. Batteries will self discharge more rapidly when stored in extreme temperatures.

TESTING

• If the test fails, fully charge the battery.
• Proper load testing of the battery requires special equipment and can be performed by your dealer.

DRY SHIPPED AGM BATTERIES ACTIVATION

• • Do NOT activate the battery unless it will be put into regular service within 30

days. Only use the electrolyte container supplied with the battery to activate the battery.

• • Keep the electrolyte container in place for 20 minutes or longer until the container is completely empty. If necessary, gently tap the container to empty it.
  • Once the battery is fully charged, replace the strip of caps by hand. Do NOT use a tool to install the strip.

CHARGING

• • Polaris recommends using a BatteryMINDer® 2012 AGM – 2 AMP (PN 2830438) charger, which can be ordered through your normal parts channel.
  • Nominal voltage is 12.8 Volts when fully charged. If the voltage falls below 12.5V, charge it immediately, or the battery runs the risk of sulfation.

MAINTENANCE

• • Never add any electrolyte or distilled water to the battery once the battery is in service.
  • If you do not drive the vehicle for more than TWO weeks, maintain the battery with the BatteryMINDer® 2012 AGM – 2 AMP (PN 2830438) charger.
  • If you plan to store the vehicle for ONE month or longer, remove the battery from the vehicle and store the battery in a cool / dry location. Continue to maintain the battery with the BatteryMINDer® 2012 AGM – 2 AMP (PN 2830438) charger and inspect the battery every 60 days.

TESTING

• • If the test fails, fully charge the battery.
  • If the battery is too low to accept a charge, see the AGM Battery Charging – Deeply Discharged (Below 3 Volts) procedure in the Service Manual.
  • Proper load testing of the battery requires special equipment and can be performed by your dealer.

LOW MAINTENANCE BATTERY BEST PRACTICES

Some Polaris ORV models include either a Lead Acid or Absorbed Glass Mat (AGM) Low Maintenance battery. See the Service Manual for procedures on how to charge, maintain, and test a Lead Acid or AGM Low Maintenance battery.

Using a new battery that has not been fully charged can damage the battery and result in a shorter life. It can also hinder vehicle performance.

NOTICE

LEAD ACID LOW MAINTENANCE BATTERY

CHARGING

• The battery must be fully charged before use or battery life will be significantly reduced by 10-30% of the battery’s full potential.
• Nominal voltage is 12.6 to 12.8 Volts when fully charged. If the voltage falls below 12.5V, charge it immediately, or the battery service life and vehicle performance may be affected.
• Polaris recommends using a BatteryMINDer® 12V 1.5 AMP Convertible (PN 2830511) charger (or a similar charger), which can be ordered through your normal parts channel.
• Charge the battery with a charging output no larger than 10% of the battery’s amp-hour rating.

MAINTENANCE

• Recharge the battery to its full capacity every 30 to 60 days.
• If the battery is stored or used in a partially charged condition, hard crystal sulfation will form on the plates, reducing the efficiency and service life of the battery.
• Never add electrolyte or distilled water to the battery. Doing so will damage the case and shorten the life of the battery.
• Store the battery in the vehicle with the cables disconnected, or store the battery in a cool / dry location. Batteries will self discharge more rapidly when stored in extreme temperatures.

TESTING

• Test the battery using the PU-50296 battery tester.
• Proper load testing of the battery requires special equipment and can be performed by your dealer.

AGM LOW MAINTENANCE BATTERIES

CHARGING

• • Polaris recommends using a BatteryMINDer® 2012 AGM – 2 AMP (PN 2830438) charger, which can be ordered through your normal parts channel.
  • Nominal voltage is 12.6–12.8 Volts when fully charged. If the voltage falls below 12.5V, charge it immediately, or the battery runs the risk of sulfation.

MAINTENANCE

• • Never add electrolyte or distilled water to the battery. Doing so will damage the case and shorten the life of the battery.
  • If you do not drive the vehicle for more than TWO weeks, maintain the battery with the BatteryMINDer® 2012 AGM – 2 AMP (PN 2830438) charger.
  • If you plan to store the vehicle for ONE month or longer, remove the battery from the vehicle and store the battery in a cool / dry location. Continue to maintain the battery with the BatteryMINDer® 2012 AGM – 2 AMP (PN 2830438) charger and inspect the battery every 60 days.

TESTING

• • If the test fails, fully charge the battery.
  • If the battery is too low to accept a charge, see the AGM Battery Charging – Deeply Discharged (Below 3 Volts) procedure in the Service Manual.
  • Proper load testing of the battery requires special equipment and can be performed by your dealer.

SUSPENSION ADJUSTMENT

FRONT/REAR SPRING PRELOAD ADJUSTMENT

The factory setting is appropriate for nearly all riding conditions. If desired, the suspension may be adjusted to maintain vehicle clearance height when carrying loads.

To adjust the preload, do the following:

1. Elevate the vehicle to allow the suspension to fully extend.
2. Turn the adjusting ring to the left to increase preload for a higher ride height. Turn the adjusting ring to the right to decrease preload for a lower ride height.

FACTORY PRELOAD SETTINGS
Sportsman XP 1000 S	Front Suspension	15.63 in. (39.7 cm)
	Rear Suspension	15.56 in. (39.5 cm)

Follow these guidelines if you make adjustments to this suspension.

• • Always return the suspension to the factory setting after the load is removed from the vehicle. The increased suspension height will negatively impact vehicle stability when operating without a load.
  • Always apply the same adjustment setting to both sides of the vehicle.
  • Do not increase the spring preload by more than one inch (25.4 mm) over the factory setting.
  • When decreasing preload, make sure at least two turns of preload are holding the spring between the retainer on the top of the shock and the threaded spring preload adjuster nut on the shock body. Failure to do so could cause the retainer to fall off when the suspension is fully extended.

CROSSOVER RING ADJUSTMENT

To adjust the preload, do the following:

1. Elevate the vehicle to allow the suspension to fully extend.
2. Using the spanner tool included with the vehicle, unlock the cross-over adjustment ring.
3. Adjust cross-over ring to desired location.
4. Lock the cross-over adjustment ring.

CROSSOVER RING FACTORY SETTINGS
Front Suspension	2 in. (5 cm)

HIGH/LOW SPEED COMPRESSION ADJUSTMENT

Always adjust the clicker at least one click below full stiff (full clockwise) or shock damage will occur.

NOTICE

HIGH SPEED COMPRESSION (RED)

To adjust high speed compression dampening, do the following:

1. Turn the outside clicker q clockwise to increase compression damping.
2. To decrease high speed compression damping, turn the outside clicker counter-clockwise.

LOW SPEED COMPRESSION (BLACK)

To adjust high speed compression dampening, do the following:

1. Turn the inside clicker w clockwise to increase compression damping.
2. To decrease high speed compression damping, turn the inside clicker counter-clockwise.

FACTORY CLICKER SETTINGS
Front/Rear High-Speed Suspension	8 Clicks from full Stiff
Front/Rear Low-Speed Suspension	5 Clicks from full Stiff

REBOUND DAMPING ADJUSTMENT

Increase the rebound damping force by turning the adjuster clockwise to increase the stiffness. Decrease the rebound damping force by turning the adjuster counterclockwise to increase the softness. The maximum adjustment for this adjuster is the fully turned in position. The minimum adjustment is 9 clicks out from the maximum position.

FACTORY CLICKER SETTINGS
Rebound Adjuster	5 Clicks from Full Stiff

HANDLEBARS

The handlebars can be adjusted for rider preference.

Improper adjustment of the handlebars or incorrect torquing of the adjuster block tightening bolts can cause limited steering or loosening of the handlebars, resulting in loss of control and serious injury or death. Follow the adjustment procedures exactly, or see your POLARIS dealer for service.

WARNING

1. Remove the upper headlight pod.
2. Loosen the four handlebar bolts.
3. Adjust the handlebar to the desired height. Be sure the handlebars do not contact the gas tank or any other part of the machine when turned fully to the left or right.
4. Torque the front two bolts to specification, then torque the rear two bolts. A gap of up to 1/8″ (3 mm) will remain at the rear of the clamp blocks.

Handlebar Bolts:

20 ft-lbs (27 N·m)

TORQUE

1. Reinstall the headlight pod.

Test for full, free range of motion by turning the handlebars side to side.

NOTICE

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.

Water in the PVT system could cause the drive belt to become wet and slip in the clutches. Always avoid spraying water directly toward any intake pre-filters. If water does enter the PVT intake, follow the procedure in the PVT Drying section.

Certain products, including insect repellents and chemicals, will damage plastic surfaces. Do not allow these types of products to contact the vehicle.

The best way to clean your POLARIS vehicle is with a garden hose and a pail of mild soap and water.

1. Use a professional-type washing cloth, cleaning the upper body first and the lower parts last.
2. Rinse with clean water frequently.
3. Dry surfaces with a chamois to prevent water spots.

WASHING TIPS

• • Avoid the use of harsh cleaners, which can damage the finish.
  • 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.
  • Do not use high-speed polishers/buffers on body panels, as damage or color fading may occur.

USING A HIGH PRESSURE WATER SYSTEM

Spilled oil left on engine components or in the engine area may pose a fire hazard. Use shop rags to clean any spilled oil. If needed, use a non-flammable solvent on the rag to aid in the cleaning process. Do not use any device such as pressurized water or air as this may disperse the oil onto the engine components and could pose a fire hazard.

WARNING

If a high pressure water system is used for cleaning, exercise extreme caution. The maximum pressure should not exceed 3000 psi (20684.27 kPa), 2.5 GPM (567.81 LPH) with a 40° pressure washer nozzle. Make sure to keep the pressure washer nozzle 2 ft (60 cm) from the vehicle and away from the surface being cleaned. High water pressure could remove paint and labels and damage radiator fins and/or impair a radiator’s effectiveness. High water pressure with a hot temperature could also damage brake lines with the nozzle at a close proximity even with a short exposure time. Avoid directing the water stream at the following items:

• • • Wheel bearings
    • Radiator
    • Transmission seals
    • Brakes / brake lines
    • Body panels
    • Labels and decals
    • Electrical components and wiring
    • Air intake components
    • Throttle and shift cables and controls
    • Seats

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.

STORAGE TIPS

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.

NOTICE

CLEAN THE EXTERIOR

Make any necessary repairs and clean the vehicle as recommended. See the Washing the Vehicle section.

STABILIZE THE FUEL

1. Fill the fuel tank.
2. Add POLARIS Carbon Clean Fuel Treatment or POLARIS Fuel Stabilizer or equivalent fuel treatments or stabilizers. Follow the instructions on the container for the recommended amount. Carbon Clean removes water from fuel systems, stabilizes fuel and removes carbon deposits from pistons, rings, valves and exhaust systems.
3. Allow the engine to run for 15-20 minutes to allow the stabilizer to disperse through the entire fuel delivery system.

OIL AND FILTER

Change the oil and filter. See the Engine Oil section.

AIR FILTER / AIR BOX

Replace the air filter. See Maintenance Chapter. Clean the air box.

FLUID LEVELS

Inspect the fluid levels. Add or change fluids as recommended in the Periodic Maintenance Chart.

• Demand drive fluid (front gearcase)
• Rear gearcase fluid (if equipped)
• Transmission fluid
• Brake fluid (change every two years and any time the fluid looks dark or contaminated)
• Coolant (test strength/fill)

INSPECT AND LUBRICATE

Inspect all cables and lubricate all areas of the vehicle as recommended in the Periodic Maintenance Chart.

FOG THE ENGINE

1. Treat the fuel system with POLARIS Carbon Clean or other equivalent fuel treatment. Follow the instructions on the container. Start the engine. Allow it to idle for several minutes so the Carbon Clean reaches the injectors. Stop the engine.
2. Remove the spark plugs and add 1–1.5 oz. (29.5–44 cc.) of engine oil. To access the plug holes, use a section of clear 6 mm (1/4”) hose and a small plastic squeeze bottle filled with the pre-measured amount of oil. Do this carefully! If you miss the plug holes, oil will drain from the spark plug cavities into the hole at the front of the cylinder head, and appear to be an oil leak.
3. Reinstall the spark plugs. Torque to specification.
4. Apply dielectric grease to the inside of each spark plug cap. Do not reinstall the cap onto the plug at this step.
5. Turn the engine over several times. Oil will be forced in and around the piston rings and ring lands, coating the cylinder with a protective film of fresh oil.
6. Reinstall the spark plug caps.
7. If POLARIS fuel system additive is not used, fuel tank, fuel lines, and injectors should be completely drained of gasoline.

BATTERY MAINTENANCE

See the Battery Storage and Battery Charging sections for storage and charging procedures.

STORAGE AREA / COVERS

Be sure the storage area is well ventilated. Cover the vehicle with a genuine POLARIS cover. Do not use plastic or coated materials. They do not allow enough ventilation to prevent condensation, and may promote corrosion and oxidation.

TRANSPORTING THE VEHICLE

Follow this procedure when transporting the vehicle:

1. Stop the engine.
2. Place the transmission in PARK.
3. Lock the temporary brake lock.
4. Secure the fuel cap, oil cap, and seats.
5. Always tie the frame of the ATV to the transporting unit securely with suitable straps or rope. Do not attach tie straps to the front A- arm bolt pockets, racks or handlebars.

Remove the key to prevent loss during transportation