PMS 419 Failure to heed the warnings and safety precautions contained in this manual can result in severe injury or death. Read this manual carefully.
WARNING Read, understand, and follow all of the instructions and safety precautions in this manual and on all product labels. Failure to follow the safety precautions could result in serious injury or death. WARNING The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects or other reproductive harm. For videos and more information about a safe riding experience with your Polaris vehicle, scan this QR code with your smartphone.
WELCOME Thank you for purchasing a POLARIS vehicle, and welcome to our world-wide family of POLARIS enthusiasts. Be sure to visit us online at www.polaris.com for the latest news, new product introductions, upcoming events, career opportunities and more. Here at POLARIS we proudly produce an exciting line of utility and recreational products.
POLARIS® and ACE™ are trademarks of POLARIS Industries Inc. Copyright 2015 POLARIS Industries Inc. All information contained within this publication is based on the latest product information at the time of publication. Due to constant improvements in the design and quality of production components, some minor discrepancies may result between the actual vehicle and the information presented in this publication. Depictions and/or procedures in this publication are intended for reference use only.
TABLE OF CONTENTS Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Features and Controls . . . . . . . . . . . . . . . . . . . 24 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 Winch Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . 69 Emission Control Systems . . . . . . . . . . . . . . . 80 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . 81 Specifications . .
INTRODUCTION This POLARIS vehicle is an off-road vehicle. Familiarize yourself with all laws and regulations concerning the operation of this vehicle in your area. The following signal words and symbols appear throughout this manual and on your vehicle. Your safety is involved when these words and symbols are used. Become familiar with their meanings before reading the manual. The safety alert symbol indicates a potential personal injury hazard.
INTRODUCTION WARNING Failure to heed the warnings and safety precautions contained in this manual can result in severe injury or death. Your POLARIS vehicle is not a toy and can be hazardous to operate. This vehicle handles differently than cars, trucks or other off-road vehicles. A collision or rollover can occur quickly, even during routine maneuvers like turning, or driving on hills or over obstacles, if you fail to take proper precautions.
INTRODUCTION Vehicle Identification Numbers Record your vehicle's identification numbers and key number in the spaces provided. Remove the spare key and store it in a safe place. An ignition key can be duplicated only by ordering a POLARIS key blank (using your key number) and mating it with one of your existing keys. The ignition switch must be replaced if all keys are lost.
SAFETY Safety Training Safety training is a top priority for POLARIS. POLARIS strongly encourages you and any family members who will be riding this vehicle to take a training course. ROHVA (Recreational Off-Highway Vehicle Association) provides both an online safety e-course and a hands-on safety course. Visit www.rohva.org or call 866-267-2751. Your POLARIS vehicle is considered an off-road vehicle. Familiarize yourself with all laws and regulations concerning the operation of this vehicle in your area.
SAFETY Safe Riding Gear Always wear helmet, eye protection, gloves, long-sleeve shirt, long pants, over-the-ankle boots and seat belt at all times. Protective gear reduces the chance of injury. Helmet Wearing a helmet can prevent a severe head injury. Whenever riding this POLARIS vehicle, always wear a helmet that meets or exceeds established safety standards. Approved helmets in the USA and Canada bear a U.S. Department of Transportation (DOT) label.
SAFETY Safe Riding Gear Eye Protection Do not depend on eyeglasses or sunglasses for eye protection. Whenever riding this POLARIS vehicle, always wear shatterproof goggles or use a shatterproof helmet face shield. POLARIS recommends wearing approved Personal Protective Equipment (PPE) bearing markings such as VESC 8, V-8, Z87.1, or CE. Make sure protective eye wear is kept clean. Gloves Wear gloves for comfort and for protection from sun, cold weather and other elements.
SAFETY Safety Labels and Locations Warning labels have been placed on the vehicle for your protection. Read and follow the instructions of the labels on the vehicle carefully. If any of the labels depicted in this manual differ from the labels on your vehicle, always read and follow the instructions of the labels on the vehicle. If an informational or graphic label becomes illegible or comes off, contact your POLARIS dealer to purchase a replacement.
SAFETY Safety Labels and Locations General Warning WARNING Require Proper Use of Your Vehicle Do your part to prevent injuries: • Do not allow careless or reckless driving. • Make sure operators are 16 or older with a valid driver’s license. • Do not let people drive after using alcohol or drugs. • Do not allow operation on public roads (unless designated for off-highway vehicle access) - collisions with cars and trucks can occur. • Do not exceed seating capacity: 1 occupant.
SAFETY Safety Labels and Locations Load/Passenger/Tire Pressure Warning WARNING • Never carry passengers in cargo box. • Passengers can be thrown off. This can cause serious injury or death. Load/Passenger/Tire Pressure Warning WARNING IMPROPER TIRE PRESSURE OR OVERLOADING CAN CAUSE LOSS OF CONTROL RESULTING IN SERIOUS INJURY OR DEATH. • Reduce speed and allow greater distance for braking when carrying cargo.
SAFETY Safety Labels and Locations PVT System Warning WARNING Improper service or maintenance of this PVT system can result in vehicle damage, SEVERE INJURY or DEATH. Always look for and remove debris inside and around clutch and vent system when replacing belt. Read owner's manual or see authorized Polaris dealer. 7177469 PVT System Warning Hitch Capacity Label TRAILER MAX WEIGHT: 1500 LBS. (682 KG) ON LEVEL GROUND 850 LBS. (386 KG) UP TO 15 DEGREES HITCH MAX. VERTICAL WEIGHT: 150 LBS.
SAFETY Safety Warnings WARNING Failure to operate this vehicle properly can result in a collision, loss of control, accident or rollover, which may result in serious injury or death. Heed all safety warnings outlined in this section of the owner’s manual and in the safety DVD provided with your vehicle. See the OPERATION section of the owner’s manual for proper operating procedures. Operating Without Instruction Operating this vehicle without proper instruction increases the risk of an accident.
SAFETY Safety Warnings Failure to Inspect Before Operating Failure to inspect and verify that the vehicle is in safe operating condition before operating increases the risk of an accident. Always perform the pre-ride inspection before each use of your vehicle to make sure it's in safe operating condition. See page 51. Always follow the inspection and maintenance procedures and schedules described in this owner’s manual. See page 81.
SAFETY Safety Warnings Carrying a Passenger This POLARIS vehicle is a single-rider vehicle. Carrying a passenger greatly reduces the operator's ability to control the vehicle, which may result in an accident or rollover. Carrying a passenger in the cargo box could result in a fall from the vehicle or contact with moving components. Never carry a passenger on this vehicle. Operating With a Load on the Vehicle The weight of both cargo and operator impacts vehicle operation and stability.
SAFETY Safety Warnings Improper Tire Maintenance Operating this vehicle with improper tires or with improper or uneven tire pressure could cause loss of control or accident. Always use the size and type of tires specified for your vehicle. Always maintain proper tire pressure as described in the owner's manual and on safety labels. Operating on Pavement This vehicle's tires are designed for off-road use only, not for use on pavement.
SAFETY Safety Warnings Turning Improperly Turning improperly could cause loss of traction, loss of control, accident or rollover. Always follow proper procedures for turning as described in this owner’s manual. Avoid sharp turns. Never turn while applying heavy throttle. Never make abrupt steering maneuvers. Practice turning at slow speeds before attempting to turn at faster speeds. Jumps and Stunts Exhibition driving increases the risk of an accident or rollover.
SAFETY Safety Warnings Crossing Hillsides Driving on a sidehill is not recommended. Improper procedure could cause loss of control or rollover. Avoid crossing the side of any hill unless absolutely necessary. If crossing a hillside is unavoidable, always follow proper procedures as described in this owner's manual. See page 61. Stalling While Climbing a Hill Stalling or rolling backwards while climbing a hill could cause a rollover. Maintain a steady speed when climbing a hill.
SAFETY Safety Warnings Operating Improperly in Reverse Improperly operating in reverse could result in a collision with an obstacle or person. Always follow proper operating procedures as outlined in this manual. See page 65. Before shifting into reverse gear, always check for obstacles or people behind the vehicle. When it's safe to proceed, back slowly.
SAFETY Safety Warnings Operating Through Water Operating through deep or fast-flowing water can cause loss of traction, loss of control, rollover or accident. Never operate in fast-flowing water or in water that exceeds the floor level of the vehicle. Always follow proper procedures for operating in water as described in this owner’s manual. See page 63. Wet brakes may have reduced stopping ability. After leaving water, test the brakes. Apply them lightly several times while driving slowly.
SAFETY Safety Warnings Improper Cargo Loading Overloading the vehicle or carrying/towing cargo improperly may cause changes in stability and handling, which could cause loss of control or an accident. • Always follow the instructions in this owner’s manual for carrying cargo. See page 66. • Never exceed the stated load capacity for this vehicle. See page 12. • Cargo should be properly distributed and securely attached. See page 66. • Reduce speed when carrying cargo or pulling a trailer.
SAFETY Safety Warnings Exposure to Exhaust Engine exhaust fumes are poisonous and can cause loss of consciousness or death in a short time. Never start the engine or let it run in an enclosed area. Operate this vehicle only outdoors or in well-ventilated areas. Hot Exhaust Systems Exhaust system components are very hot during and after use of the vehicle. Hot components can cause burns and fire. Do not touch hot exhaust system components. Always keep combustible materials away from the exhaust system.
FEATURES AND CONTROLS Component Locations Single-Rider Seat ROPS Frame Steering Wheel Hip Bars Cargo Box Front Box Cover Taillights Headlights Engine Intake Pre-Filter Cab Nets Brush Guard Radiator Brake Pedal 24 Throttle Pedal Fuel Cap Shifter
FEATURES AND CONTROLS Trailer Receiver Hitch Bracket This vehicle is equipped with a receiver hitch bracket for a trailer hitch. Trailer towing equipment is not supplied with this vehicle. To avoid injury and property damage, always heed the warnings and towing capacities outlined on pages 66-68. Service Access Panels Receiver Hitch Access serviceable engine components through the engine access panel behind the seat. Remove the seat and release the access panel latches to remove the access panel.
FEATURES AND CONTROLS Steering Wheel The steering wheel can be tilted upward or downward for rider preference. Lift and hold the steering wheel adjustment lever while moving the steering wheel upward or downward. Release the lever when the steering wheel is at the desired position. Always make sure the steering wheel position does not impede proper operation of the brake pedal, throttle pedal and all other controls.
FEATURES AND CONTROLS Cab Nets Riding in this vehicle Cab Net Latches without using the cab nets (or doors, if equipped) increases the risk of serious injury or death in the event of an accident or rollover. Cab nets (or doors) must be used at all times. Make sure all latches on both sides of the vehicle are secure before operating the vehicle. Always inspect cab nets and latches for tightness, wear and damage before each use of the vehicle. Use the strap adjusters to tighten any loose straps.
FEATURES AND CONTROLS Fuel Cap The fuel tank filler cap is located on the right side of the vehicle near the seat. When refueling, always use either leaded or unleaded gasoline with a minimum pump octane number of 87 R+M/2 octane. Do not use fuel with ethanol content greater than 10 percent, such as E-85 fuel. Fuel Cap Seat Seat Adjustments Always make sure the seat position allows for proper access and operation of the brake pedal, throttle pedal and all other controls.
FEATURES AND CONTROLS Seat Belt This POLARIS vehicle is equipped with three-point lap and diagonal seat belts. Always secure the seat belt before riding. To wear the seat belt properly, follow this procedure: 1. Pull the seat belt latch downward and across your chest toward the buckle at the inner edge of the seat. The belt should fit snugly across your hips and diagonally across your chest. Make sure the belt is not twisted. 2. Push the latch plate into the buckle until it clicks. 3.
FEATURES AND CONTROLS Switches Instrument Cluster AWD Switch 12V Accessory Outlet Ignition Switch/Light Switch 30
FEATURES AND CONTROLS Switches Ignition Switch/Light Switch Use the ignition switch to start the engine OFF and to turn the lights on or off. The key can be removed from the switch when it is in the OFF position. OFF Turn the key to the OFF position to stop the engine. Electrical circuits are off. LIGHTS ON The lights are on. Electrical circuits are on. Electrical equipment can be used. LIGHTS OFF The lights are off. Electrical circuits are on. Electrical equipment can be used.
FEATURES AND CONTROLS Gear Selector To change gears, stop the vehicle, and with the engine idling, move the lever to the desired gear. Do not attempt to shift gears with engine speed above idle or while the vehicle is moving. P: Park R: Reverse N: Neutral L: Low Gear H: High Gear Gear Selector NOTICE: Do not attempt to shift the transmission while the vehicle is moving or damage to the transmission could result. Always shift when the vehicle is stationary and the engine is at idle.
FEATURES AND CONTROLS Brake Pedal Depress the brake pedal to slow or stop the vehicle. Apply the brakes while starting the engine. Throttle Pedal Push the pedal down to increase engine speed. Spring pressure returns the pedal to the rest position when released. Always check that the throttle pedal returns normally before starting the engine. Make sure there's adequate throttle pedal freeplay. See page 109.
FEATURES AND CONTROLS Rollover Protective Structure (ROPS) The Rollover Protective Structure (ROPS) on this vehicle meets OSHA 1928.53 rollover performance requirements. Always have your authorized POLARIS dealer thoroughly inspect the ROPS if it ever becomes damaged in any way. No device can assure occupant protection in the event of a rollover. When used with seat belts and cab nets, the ROPS helps prevent occupants from being ejected from the vehicle.
FEATURES AND CONTROLS All Wheel Drive (AWD) System The All Wheel Drive system is controlled by the AWD switch. When the switch is on 2WD (2X4), AWD the vehicle is in two-wheel drive at all times. When the switch is on AWD (4x4), the vehicle is in all wheel drive and the 4X4 indicator in the instrument cluster will be on. When in AWD, the demand drive unit will 2WD automatically engage any time the rear wheels lose traction.
FEATURES AND CONTROLS Instrument Cluster High water pressure may damage components. Wash the vehicle by hand or with a garden hose using mild soap. Do not use alcohol to clean the instrument cluster. Do not allow insect sprays to contact the lens. Speedometer Indicator Lamps Speedometer The speedometer displays vehicle speed in either miles per hour (MPH) or kilometers per hour (km/h). See page 40. Mode Button Use the MODE button to toggle through mode options. See page 40 for operation of the modes.
FEATURES AND CONTROLS Instrument Cluster Indicator Lamps Lamp Indicates Condition When standard mode is selected, speed displays in Vehicle miles per hour. Speed When metric mode is selected, speed displays in kilometers per hour. Over This lamp illuminates to indicate an overheated Temperature engine. If the indicator flashes, the overheating condition remains, and the system will automatically reduce engine power.
FEATURES AND CONTROLS Instrument Cluster Rider Information Center The rider information center is located in the instrument cluster. All segments will light up for one second at start-up. If the instrument cluster fails to illuminate, a battery over-voltage may have occurred and the instrument cluster may have shut off to protect the electronic speedometer. If this occurs, your POLARIS dealer can provide proper diagnosis.
FEATURES AND CONTROLS Instrument Cluster Rider Information Center 2. Fuel Gauge - The segments of the fuel gauge show the level of fuel in the fuel tank. When the last segment clears, a low fuel warning is activated. All segments including the fuel icon will flash. Refuel immediately. Tip: If the fuel icon fails to display, an open or short circuit has occurred in the fuel sensor circuit. Your authorized POLARIS dealer can assist. 3.
FEATURES AND CONTROLS Instrument Cluster Rider Information Center Use the MODE button to toggle through the information area options. Display Units (Standard/Metric) The display can be changed to show either standard or metric units of measurement for each of the following settings. MODE Button Tip: To exit the set-up mode, turn the key off. Wait 5 seconds, then turn the key on. The gauge display the mode that was displayed prior to setting the units.
FEATURES AND CONTROLS Instrument Cluster Rider Information Center Clock Mode Tip: The clock must be reset any time the battery has been disconnected or discharged. 1. Turn the key to the ON position. Use the MODE button to toggle to the odometer display. 2. Press and hold the MODE button until the hour segment flashes. Release the button. 3. With the segment flashing, tap the MODE button to advance to the desired setting. 4. Press and hold the MODE button until the next segment flashes. Release the button.
FEATURES AND CONTROLS Instrument Cluster Rider Information Center Programmable Service Interval When the hours of engine operation equal the programmed service interval setting, the wrench icon will flash for 5 seconds each time the engine is started. When this feature is enabled, it provides a convenient reminder to perform routine maintenance. The service interval is programmed at 50 hours at the factory. Use the following procedure to change the service interval. 1.
FEATURES AND CONTROLS Instrument Cluster Rider Information Center Engine Error Codes Suspect Parameter Error Code The error screen displays Number (SPN) Number (0-9) only when the CHECK ENGINE light is on or when it goes on and off during one ignition cycle. Error codes are not stored. When the key is turned OFF, the code and message is lost, but will reappear if the fault reoccurs after restarting the engine.
FEATURES AND CONTROLS Instrument Cluster Diagnostic Display Code Definitions Open Load: There is a break in the wires that lead to the item listed in the chart (injector, fuel pump, etc.), or the item has failed. Short-to-Ground: The wire is shorted to ground between the electronic control unit and the item listed in the chart. Shorted Load: The wires leading to the item listed in the chart are shorted together, or the item has shorted internally.
FEATURES AND CONTROLS Instrument Cluster Diagnostic Display Code Definitions Diagnostic Codes Component Condition SPN FMI Intake Air Temperature Sensor Data Erratic, Intermittent Or Incorrect Voltage Above Normal, Or Shorted To High Source Voltage Below Normal, Or Shorted To Low Source Abnormal Rate Of Change Data Valid But Above Normal Operating Range - Least Severe Level Data Valid But Above Normal Operational Range - Most Severe Level Data Erratic, Intermittent Or Incorrect Voltage Above Normal, Or
FEATURES AND CONTROLS Instrument Cluster Diagnostic Display Code Definitions Diagnostic Codes Component Fan Relay Driver Circuit Ignition Coil Primary Driver 1 (Front) (MAG) Fuel Pump Driver Circuit Oxygen Sensor 1 ECU Output Supply Voltage 1 ECU Output Supply Voltage 2 ECU Output Supply Voltage 3 ETC Accelerator Position Sensor Outputs 1 & 2 Correlation 46 Condition SPN FMI Voltage Above Normal, Or Shorted To High Source Voltage Below Normal, Or Shorted To Low Source Current Below Normal Or Open C
FEATURES AND CONTROLS Instrument Cluster Diagnostic Display Code Definitions Diagnostic Codes Component Throttle Position Sensor 2 Active Descent Control System Fuel Correction Front All Wheel Drive Control Circuit Oxygen Sensor Heater 1 Accelerator Position/Brake Position Interaction Throttle Position Sensor (1 or 2 Indeterminable) Throttle Body Control Power Stage Throttle Body Control Return Spring Check Failed Throttle Body Control Adaption Aborted Throttle Body Control Limp Home Position Check Fai
FEATURES AND CONTROLS Instrument Cluster Diagnostic Display Code Definitions Diagnostic Codes Component Throttle Body Control - Position Deviation Fault ECU Monitoring Error ECU Monitoring Error (Level 3) ECU Monitoring of Injection Cut Off (Level 1) ECU Monitoring of Injection Cut Off (Level 2) Throttle Body Control - Requested Throttle Angle Not Plausible ECU ADC Fault - No Load ECU ADC Fault - Voltage Accelerator Sensor Sync Fault - Sensor Diff Exceeds Limit ECU Fault - ICO ECU Fault - Hardware Disruptio
OPERATION WARNING Failure to operate the vehicle properly can result in a collision, loss of control, accident or rollover, which may result in serious injury or death. Read and understand all safety warnings outlined in the safety section of this owner’s manual. Vehicle Break-in Period The break-in period for your new POLARIS vehicle is the first 25 hours of operation, or the time it takes to use the first two tanks full of gasoline.
OPERATION Vehicle Break-in Period Engine and Drivetrain Break-in 1. Fill the fuel tank with gasoline. See page 28. Always exercise extreme caution whenever handling gasoline. 2. Check the oil level. See page 88 (325) or page 91 (570). Add the recommended oil as needed to maintain the oil level in the safe operating range. 3. Complete the New Operator Driving Procedures outlined on pages 56-57. 4. Avoid aggressive use of the brakes. 5. Vary throttle positions. Do not operate at sustained idle. 6.
OPERATION Pre-Ride Inspection Failure to inspect and verify that the vehicle is in safe operating condition before operating increases the risk of an accident. Always inspect the vehicle before each use to make sure it's in safe operating condition.
OPERATION Safe Operation Practices 1. Visit the Recreational Off-Highway Vehicle Association web site and take the free on-line training course. Complete the recommended safety training before operating this vehicle. Visit www.rohva.org or call 866-267-2751. 2. Do not allow anyone under 16 years of age or without a valid driver’s license to operate this vehicle. 3. Never carry a passenger on this vehicle. 4. Engine exhaust fumes are poisonous. Never start the engine or let it run in an enclosed area. 5.
OPERATION Safe Operation Practices 12. Never operate the vehicle on a frozen body of water unless you have first verified that the ice is sufficiently thick to support the weight and moving force of the vehicle, you and your cargo, together with any other vehicles in your party. 13. Do not touch hot exhaust system components. Always keep combustible materials away from the exhaust system. 14. Always remove the ignition key when the vehicle is not in use to prevent unauthorized use.
OPERATION Starting the Engine 1. Position the vehicle on a level surface outdoors or in a wellventilated area. 2. Sit in the driver's seat and fasten the seat belt. Secure the cab nets. 3. Place the transmission in PARK. 4. Apply the brakes. Do not press the throttle pedal while starting the engine. 5. Turn the ignition key to the START position. Engage the starter for a maximum of five seconds. Release OFF START the key when the engine starts. Turn the key to either LIGHTS ON or LIGHTS OFF. 6.
OPERATION Stopping the Engine 1. Release the throttle pedal completely and brake to a complete stop. 2. Place the transmission in PARK. 3. Turn the engine off. Braking 1. Release the throttle pedal completely. (When the throttle pedal is released completely and engine speed slows to near idle, the vehicle has no engine braking.) 2. Press on the brake pedal evenly and firmly. Practice starting and stopping (using the brakes) until you're familiar with the controls. Parking the Vehicle 1.
OPERATION New Operator Driving Procedures 1. Read and understand the owner's manual and all warning and instruction labels before operating this vehicle. 2. Visit the Recreational Off-Highway Vehicle Association web site and take the free on-line training course. Visit www.rohva.org or call 866-267-2751. Hands-on training is also available through ROHVA. 3. Perform the pre-ride inspection. See page 51. 4. Do not tow or carry cargo during this period. 5.
OPERATION New Operator Driving Procedures 11. Apply the brakes and shift into low gear. 12. Check your surroundings and determine your path of travel. 13. Keeping both hands on the steering wheel, slowly release the brakes and depress the throttle with your right foot to begin driving. 14. Drive slowly at first. On level surfaces, practice starting, stopping, turning, maneuvering, using the throttle and brakes and driving in reverse.
OPERATION Turning the Vehicle Your vehicle is equipped with a solid rear axle, which drives both rear wheels equally at all times. This means that the wheel on the outside of the turn must travel a greater distance than the inside wheel when turning and the inside tire must slip traction slightly. To turn the vehicle, rotate the steering wheel in the direction of the turn. Practice making turns at slow speeds before attempting to turn at faster speeds.
OPERATION Driving on Slippery Surfaces Sideways skid Turn in direction of skid When driving on slippery surfaces such as wet trails, loose gravel, or ice, be alert for the possibility of skidding and sliding. Follow these precautions when encountering slippery conditions: 1. Do not operate on excessively rough, slippery or loose terrain. 2. Slow down before entering slippery areas. 3. Maintain a high level of alertness, reading the trail and avoiding quick, sharp turns, which can cause skids. 4.
OPERATION Driving Uphill Whenever traveling uphill, follow these precautions: 1. Always check the terrain carefully before ascending any hill. Never drive on hills with excessively slippery or loose surfaces. 2. Never operate in TURF mode (if equipped) while operating on a hill or other irregular terrain. Always move the AWD switch to AWD before ascending or descending a hill. 3. Avoid excessively steep hills. If ascending a steeper grade is unavoidable, engage all-wheel drive before ascending. 4.
OPERATION Driving on a Sidehill (Sidehilling) Driving on a sidehill is not recommended. Improper procedure could cause loss of control or rollover. Avoid crossing the side of any hill unless absolutely necessary. If crossing a hill is unavoidable, follow these precautions: 1. Engage all-wheel drive. 2. Never operate in TURF mode (if equipped) while operating on a hill or other irregular terrain. Always move the AWD switch to AWD before ascending or descending a hill. 3.
OPERATION Driving Downhill Whenever descending a hill, follow these precautions: 1. Avoid excessively steep hills. 2. Never operate in TURF mode (if equipped) while operating on a hill or other irregular terrain. Always move the AWD switch to AWD before ascending or descending a hill. 3. Slow down. Never travel down a hill at high speed. 4. Always check the terrain carefully before descending a hill. Never drive on hills with excessively slippery or loose surfaces. 5.
OPERATION Driving Through Water Your vehicle can operate through water with a maximum recommended depth equal to floor level. Follow these precautions when operating through water: 1. Determine water depth and current before entering water. 2. Choose a crossing where the water level is lowest and where both banks have gradual inclines. Never operate in water that exceeds the maximum recommended depth.
OPERATION Driving Over Obstacles Follow these precautions when operating over obstacles: 1. Always check for obstacles before operating in a new area. 2. Look ahead and learn to read the terrain. Be constantly alert for hazards such as logs, rocks and low hanging branches. 3. Travel slowly and use extra caution when operating on unfamiliar terrain. Not all obstacles are immediately visible. 4. Avoid operating over large obstacles such as large rocks and fallen trees.
OPERATION Driving in Reverse Follow these precautions when operating in reverse: 1. Always check for obstacles or people behind the vehicle. 2. Apply the throttle lightly. Never apply throttle suddenly. 3. Back slowly. 4. Apply the brakes lightly for stopping. 5. Avoid making sharp turns. Parking on an Incline A rolling vehicle can result in serious injury. Avoid parking on an incline. If parking on an incline is unavoidable, follow these precautions: 1. Place the transmission in PARK. 2.
OPERATION Hauling Cargo WARNING Overloading the vehicle or carrying or towing cargo improperly can alter vehicle handling and may cause loss of control or brake instability. Always follow these precautions when hauling cargo: Never exceed the stated load capacity for this vehicle. REDUCE SPEED AND ALLOW GREATER DISTANCES FOR BRAKING WHEN HAULING CARGO. NEVER EXCEED THE MAXIMUM WEIGHT CAPACITY of the vehicle.
OPERATION Hauling Cargo Your POLARIS vehicle has been designed to carry or tow specific capacities. Reduce speed and allow a greater distance for braking when carrying cargo. Loads should be centered and carried as low as possible in the box. For stability on rough or hilly terrain, reduce both speed and cargo. Exercise caution if the cargo load extends over the side of the box. Always read and understand the load distribution warnings listed on warning labels and in this manual.
OPERATION Towing Loads WARNING Towing improperly can alter vehicle handling and may cause loss of control or brake instability. Always follow these precautions when towing: 1. Never load more than 150 lbs. (68.1 kg) tongue weight on the towing bracket. 2. When towing a disabled vehicle, place the disabled vehicle’s transmission in neutral. Do not operate the vehicle faster than 10 MPH (16 km/h) when towing. 3. Towing a trailer increases braking distance.
WINCH GUIDE These safety warnings and instructions apply if your vehicle came equipped with a winch or if you choose to add an accessory winch to your vehicle. WARNING Improper winch use can result in SEVERE INJURY or DEATH. Always follow all winch instructions and warnings in this manual. Your winch may have a cable made of either wire rope or specially designed synthetic rope. The term “winch cable” will be used for either unless noted otherwise. Winch Safety Precautions 1. 2. 3. 4. 5. 6. 7. 8. 9.
WINCH GUIDE Winch Safety Precautions 10. Always apply your vehicle’s park brake and/or park mechanism to hold the vehicle in place during winching. Use wheel chocks if needed. 11. Always align the vehicle and winch with the load directly in front of the vehicle as much as possible. Avoid winching with the winch cable at an angle to the winching vehicle’s centerline whenever possible. 12. If winching at an angle is unavoidable, follow these precautions: A. B. Look at the winch drum occasionally.
WINCH GUIDE Winch Safety Precautions 18. Never release the clutch on the winch when the winch cable is under load. 19. Never use the winch for lifting or transporting people. 20. Never use the winch to hoist or suspend a vertical load. 21. Never immerse or submerse your winch in water. Your dealer can provide service on your winch if this occurs. 22. Always inspect your winch and winch cable before each use. 23. Never winch the hook fully into the winch. This can cause damage to winch components. 24.
WINCH GUIDE Winch Operation Read the Winch Safety Precautions in the preceding pages before using your winch. Tip: Consider practicing the operation and use of your winch before you actually need to use it in the field. WARNING Improper winch use can result in SEVERE INJURY or DEATH. Always follow all winch instructions and warnings in this manual. Each winching situation is unique. • Take your time to think through the winching you are about to do. • Proceed slowly and deliberately.
WINCH GUIDE Winch Operation 4. Always use the hook strap when handling the hook. WARNING! Never put your fingers into the hook. This could lead to SEVERE INJURY. A. Attach the hook itself onto the load or use a tow strap or chain NO YES to secure the load to the winch cable. Tip: A “tow strap” is NOT intended to stretch. A “recovery strap” is designed to stretch. WARNING! Never use a recovery strap when winching due to the excessive energy that can be released if the winch cable breaks.
WINCH GUIDE Winch Operation 5. Never remove the hook strap from the hook. 6. Release the winch clutch and pull out the winch cable. 7. Pulling out as much cable as possible maximizes the winch’s pulling capacity. Always be sure that at least five (5) full turns of winch cable are wrapped around the winch drum at all times. The friction provided by this wrapped cable allows the drum to pull on the winch cable and move the load. 8.
WINCH GUIDE Winch Operation 11. The ONLY time a winch-equipped vehicle should be moving when using the winch is when that vehicle itself is stuck. The winchequipped vehicle should NEVER be in motion to “shock” load the winch cable in an attempt to move a second stuck vehicle. See the Shock Loading section on page 78. For your safety, always follow these guidelines when winching a vehicle free: A. Release the winch clutch and spool out the necessary length of winch cable. B.
WINCH GUIDE Winch Operation 14. The winch motor may become hot during winch use. If you winch for more than 45 seconds, or if the winch stalls during operation, stop winching and permit the winch to cool down for 10 minutes before using it again. 15. After winching is complete, especially if winching at an angle, it may be necessary to re-distribute the winch cable across the winch drum. You will need an assistant to perform this task. A. B. C. D. E. F. 76 Release the clutch on the winch.
WINCH GUIDE Winch Cable Care For your safety, always replace POLARIS winch parts (including the cable) with genuine POLARIS replacement parts available at your authorized POLARIS dealer. WARNING! Use of worn or damaged cable could lead to sudden failure and SEVERE INJURY. 1. Always inspect your winch before each use. Inspect for worn or loose parts including mounting hardware. Never use the winch if any part needs repair or replacement. 2. Always inspect your winch cable before each use.
WINCH GUIDE Shock Loading WARNING! Your winch cable is very strong but it is NOT designed for dynamic, or “shock” loading. Shock loading may tension a winch cable beyond its strength and cause the cable to break. The end of a broken winch cable under such high loading can cause SEVERE INJURY or DEATH to you and other bystanders. Winch cables are designed to NOT absorb energy. This is true of both wire-rope and synthetic-rope winch cables. 1. Never attempt to “jerk” a load with the winch.
WINCH GUIDE Winch Maintenance and Service Safety WARNING! Improper or lack of winch maintenance and service could lead to SEVERE INJURY or DEATH. Always follow all winch instructions and warnings in this manual. 1. Always inspect your winch before each use. Inspect for worn or kinked winch cable. Also inspect for worn or loose parts including mounting hardware. 2. Permit your winch motor to cool down prior to servicing your winch. 3.
EMISSION CONTROL SYSTEMS Noise Emission Control System Do not modify the engine, intake or exhaust components, as doing so may affect compliance with U.S.A. EPA noise control requirements (40 CFR 205) and local noise level requirements. Operation on Public Lands in the U.S.A. Your POLARIS vehicle has a spark arrester that was tested and qualified to be in accordance with the USFS standard 5100-1C.
MAINTENANCE Periodic Maintenance Chart Any qualified repair shop or person may maintain, replace or repair the emission control devices or systems on your vehicle. An authorized POLARIS dealer can perform any service that may be necessary for your vehicle. POLARIS also recommends POLARIS parts for emissions-related service, however equivalent parts can be used.
MAINTENANCE Periodic Maintenance Chart Maintenance Chart Key Symbol Description Ź Perform these operations more often for vehicles subjected to severe use. D Have an authorized POLARIS dealer or other qualified person perform these services. WARNING! Improperly performing the procedures marked with a “D” could result in component failure and lead to serious injury or death. Have an authorized POLARIS dealer or other qualified person perform these services.
MAINTENANCE Periodic Maintenance Chart Item Maintenance Interval Remarks (whichever comes first) Hours Calendar Miles (Km) Ź Engine oil change 25 H 1M - Break-in oil and filter change Ź Demand drive fluid 25 H 1M - Break-in oil level check Ź Transmission oil (main gearcase) 25 H 1M - Break-in oil level check Ź Throttle cable 50 H 6M 300 (500) Inspect; adjust; lubricate; replace if necessary Throttle body air intake ducts/flange 50 H 6M 300 (500) Inspect duct for proper sealing/
MAINTENANCE Periodic Maintenance Chart Item Maintenance Interval (whichever comes first) Remarks Hours Calendar Miles (Km) Ź Wiring 100 H 12 M 1000 (1600) Inspect for wear, routing, security; apply dielectric grease to connectors subjected to water, mud, etc.
MAINTENANCE Lubrication Recommendations Check and lubricate all components at the intervals outlined in the Periodic Maintenance Chart beginning on page 81, or more often under severe use, such as wet or dusty conditions. Items not listed in the chart should be lubricated at the general lubrication interval. Item Lube Method Engine Oil PS-4 5W-50 4-Cycle Oil Add to proper level on dipstick. See page 88 (325) or page 91 (570). Brake Fluid DOT 4 Brake Fluid Maintain level between fill lines.
MAINTENANCE Lubrication Recommendations Stabilizer Bar Bushings Rear Control Arm Pivot Bushings Front A-Arm Bushing 86 Tie Rod Bushing Ball Joint Boot
MAINTENANCE Engine Oil Oil Recommendations POLARIS recommends the use of POLARIS PS-4 Full Synthetic 5W50 4-cycle oil for this engine. WARNING! Vehicle operation with insufficient, deteriorated, or contaminated engine oil will cause accelerated wear and may result in engine seizure, accident, and injury. Always perform the maintenance procedures as outlined in the Periodic Maintenance Chart. Oil may need to be changed more frequently if POLARIS PS-4 engine oil is not used.
MAINTENANCE Engine Oil Always check and change the oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 81. Always use the recommended engine oil. See page 87. NOTICE: Allowing dirt or debris to enter the engine can result in serious engine damage. Always clean away all dirt and debris from the dipstick area before removing the dipstick. Oil Check (325) The oil dipstick is located on the lower engine, behind the seat. Access the dipstick through the right rear wheel well.
MAINTENANCE Engine Oil Oil and Filter Change (325) Always check and change the oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 81. Always change the oil filter whenever changing oil. The engine drain plug is located on the bottom of the crankcase. 1. Position the vehicle on a level surface. Place the transmission in PARK. Apply the brakes. 2. Start the engine. Allow it to idle for two to three minutes. Stop the engine. 3. Clean the area around the drain plug.
MAINTENANCE Engine Oil Oil and Filter Change (325) 8. Using a clean, dry cloth, clean the oil filter cover on the crankcase. 9. Place shop towels beneath the filter cover to catch oil drips. Remove the cover screws and remove the cover to access the oil filter. 10. Remove the oil filter and spring, retaining the spring for reinstallation. 11. Using a clean, dry cloth, clean the surface of the crankcase. 12. Lubricate the o-ring for the new filter with a film of fresh engine oil.
MAINTENANCE Engine Oil Always check and change the oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 81. Always use the recommended engine oil. See page 87. Oil Check (570) The oil dipstick and fill tube is located on the engine, behind the passenger seat. Access the dipstick through the right rear wheel well. 1. Position the vehicle on a level surface. 2. Place the transmission in PARK. 3.
MAINTENANCE Engine Oil Oil and Filter Change (570) Always check and change the oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 81. Always change the oil filter whenever changing oil. The engine drain plug is located on the bottom of the crankcase. 1. Position the vehicle on a level surface. Place the transmission in PARK. Apply the brakes. 2. Start the engine. Allow it to idle for two to three minutes. Stop the engine. 3. Clean the area around the drain plug.
MAINTENANCE Engine Oil Oil and Filter Change (570) 8. Using a cap-style oil filter wrench, turn the filter counter-clockwise to remove it. 9. Using a clean dry cloth, clean the filter sealing surface on the crankcase. Make sure the old filter o-ring is completely removed. 10. Lubricate the o-ring on the new filter with a film of fresh engine oil. Check to make Oil Filter sure the o-ring is in good condition. 11.
MAINTENANCE Gearcases Demand Drive Unit (Front Gearcase) Always check and change the fluid at the intervals outlined in the Periodic Maintenance Chart beginning on page 81. Refer to the Gearcase Specifications Chart on page 96 for recommended lubricants, capacities and torque specifications. Fluid Check The fill plug is located on the bottom right side of the demand drive unit. Access the fill plug through the right front wheel well.
MAINTENANCE Gearcases Transmission (Main Gearcase) Always check and change the fluid at the intervals outlined in the Periodic Maintenance Chart beginning on page 81. Refer to the Gearcase Specifications Chart on page 96 for recommended lubricants, capacities and torque specifications. Fluid Check The fill plug is located on the rear of the gearcase. Maintain the fluid level at the bottom of the fill plug hole. 1. Position the vehicle on a level surface. 2. Remove the fill plug. Check the fluid level. 3.
MAINTENANCE Gearcases Gearcase Specification Chart Use of other fluids may result in improper operation of components. See page 134 for the part numbers of POLARIS products. Gearcase Lubricant Capacity Fill Plug Torque Drain Plug/ Level Check Plug Torque Transmission (Main Gearcase) AGL Gearcase Lubricant & Transmission Fluid 44 oz. (1300 ml) 10-14 ft. lbs. (14-19 Nm) 10-14 ft. lbs. (14-19 Nm) 9 oz. (265 ml) 8-10 ft. lbs. (11-13.6 Nm) 8-10 ft. lbs. (11-13.
MAINTENANCE Spark Plug Spark Plug Removal and Replacement 1. Remove the cargo box access panel. 2. Remove the spark plug cap. 3. Using the spark plug wrench provided in the tool kit, remove the plug by rotating it counter-clockwise. 4. Reverse the procedure for spark plug installation. Torque to specification. See page 96. Spark Plug Condition Normal Plug The normal insulator tip is gray, tan or light brown. There will be few combustion deposits. The electrodes are not burned or eroded.
MAINTENANCE Fuses If the engine stops or will not start, or if you experience other electrical failures, a fuse may need replacement. Locate and correct any short circuits that may have caused the blown fuse, then replace the fuse.
MAINTENANCE Fuses Fuse Box 1. Remove the seat to access the fuse box. 2. Squeeze the cover release tabs inward and remove the fuse box cover. 3. Remove the suspect fuse from the fuse panel. If the fuse is blown, install a new fuse with the same amperage rating. 4. Reinstall the fuse box cover. 5. Reinstall the seat. Release Tabs Power Steering Unit If your model is equipped with power steering, frequently clean the areas around and on the power steering unit to allow proper cooling.
MAINTENANCE Cooling System Operation The engine coolant level is controlled or maintained by the recovery system. The recovery system components are the overflow bottle, radiator filler neck, radiator pressure cap and connecting hose. As coolant operating temperature increases, the expanding (heated) excess coolant is forced out of the radiator, past the pressure cap, and into the overflow bottle.
MAINTENANCE Cooling System Radiator and Cooling Fan Always check and clean the screen and radiator fins at the intervals outlined in the Periodic Maintenance Chart beginning on page 81. Do not obstruct or deflect air flow through the radiator by installing unauthorized accessories in front of the radiator or behind the cooling fan. Interference with the radiator air flow can lead to overheating and consequent engine damage.
MAINTENANCE Cooling System Coolant Level Always check and change the coolant at the intervals outlined in the Periodic Maintenance Chart beginning on page 81. Maintain the coolant level between the minimum and maximum marks on the bottle (when the fluid is cool). The coolant level in the bottle can be viewed through the left front wheel well or in the compartment in the front box. 1. Position the vehicle on a Overflow level surface. Bottle Radiator 2. View the coolant level in Cap the overflow bottle. 3.
MAINTENANCE POLARIS Variable Transmission (PVT) System WARNING Failure to comply with the instructions in this warning can result in severe injury or death. Do not modify any component of the PVT system. Doing so may reduce its strength so that a failure may occur at a high speed. The PVT system has been precision balanced. Any modification will cause the system to be out of balance, creating vibration and additional loads on components.
MAINTENANCE POLARIS Variable Transmission (PVT) System Belt Replacement/Debris Removal If a belt fails, always clean any debris from the PVT intake and outlet duct and from the clutch and engine compartments when replacing the belt. WARNING! Failure to remove ALL debris when replacing the belt could result in vehicle damage, loss of control and severe injury or death. 1. Allow hot components to cool before performing this procedure. 2. Remove the clutch cover screws and open the clutch cover.
MAINTENANCE POLARIS Variable Transmission (PVT) System PVT Drying There may be some instances when water is accidently ingested into the PVT system. Use the following instructions to dry it out before operating. NOTICE: When washing the vehicle, always avoid spraying water directly toward the PVT intake duct. See page 126 for recommended washing procedures. 1. Remove the drain plug from the bottom of the clutch box. Allow the water to drain. Reinstall the drain plug securely. 2.
MAINTENANCE Air Filter Always clean all dirt and debris away from the air box area before servicing the air filter. Always change the air filter at the intervals outlined in the Periodic Maintenance Chart beginning on page 81. 1. Remove the cargo box access panel. Cover Clips (2) 2. Clean all dirt and debris from the air box area BEFORE servicing the air filter. 3. Unlatch the cover clips and carefully remove the air box cover. 4. Loosen the air filter clamp and remove the filter.
MAINTENANCE Breather Hose Inspection 1. Remove the breather hose clamp at the engine (near the exhaust outlet). 2. Pull the other end of the breather hose assembly away from the airbox. 3. Remove the breather hose assembly from the vehicle. 4. Inspect the hoses for debris. Blow gently through the hoses to check for clogging. Replace a damaged or clogged hose. 5. Check hoses for cracks, deterioration, abrasions or leaks. Replace as needed. 6. Reinstall the hose assembly and secure the clamp at the engine.
MAINTENANCE Spark Arrester WARNING Failure to heed the following warnings while servicing the spark arrester could result in serious injury or death. Never run the engine in an enclosed area. Remove any combustible materials from the area. Wear eye protection and leather work gloves. Do not stand behind or in front of the vehicle while purging. Never go under the vehicle while it's inclined. The exhaust system can get extremely hot. Do not perform service on the spark arrester while the system is hot.
MAINTENANCE Throttle System WARNING Failure to check or maintain proper operation of the throttle system can result in an accident and lead to serious injury or death if the throttle pedal sticks during operation. Never start or operate this vehicle if it has a sticking or improperly operating throttle pedal. Immediately contact your POLARIS dealer or other qualified person for service if throttle problems arise.
MAINTENANCE Throttle System Throttle Pedal Freeplay Adjustment NOTICE: Engine idle speed is established at the factory and is not adjustable. Never attempt to adjust engine idle speed by adjusting throttle pedal freeplay. At operating temperature, idle speed should be 1250 +/- 50 RPM. If engine idle speed is not satisfactory, please see your POLARIS dealer or other qualified service person. 1. Place the transmission in PARK. 2. Apply the brakes. Start the engine. Allow it to warm up thoroughly. 3.
MAINTENANCE Brakes The front and rear brakes are hydraulic disc type brakes activated by the brake pedal. See page 33. Always check brake pedal travel and the brake fluid reservoir level before each use of the vehicle. When applied, the brake pedal should feel firm. Any sponginess would indicate a possible fluid leak or low brake fluid level, which must be corrected before riding. See page 112 for brake fluid information.
MAINTENANCE Brakes Brake Fluid Inspect the level of the brake fluid before each operation. If the fluid level is low add DOT 4 brake fluid only. See page 134 for the part numbers of POLARIS products. WARNING! After opening a bottle of brake fluid, always discard any unused portion. Never store or use a partial bottle. Brake fluid is hygroscopic, meaning it rapidly absorbs moisture from the air.
MAINTENANCE Brakes Brake Inspection 1. Check the brake system for fluid leaks. 2. Check the brake pedal for excessive travel or a spongy feel. 3. Check the friction pads for wear, damage and looseness. 4. Check brake discs for signs of cracks, excessive corrosion, warping or other damage. Clean any grease using an approved brake cleaner or alcohol. 0.030" (0.762mm) WARNING! Do not apply WD-40 or any petroleum product to brake discs.
MAINTENANCE Steering Wheel Inspection Check the steering wheel for specified freeplay and smooth operation at the intervals outlined in the Periodic Maintenance Chart beginning on page 81. 1. Position the vehicle on level ground. 2. Lightly turn the steering wheel left and right. 3. There should be 0.8”-1.0” (20-25 mm) of freeplay. 4. If there is excessive freeplay or strange noises, or the steering feels rough or “catchy,” have the steering system inspected by an authorized POLARIS dealer.
MAINTENANCE Tires WARNING Operating your vehicle with worn tires will increase the possibility of skidding, loss of control and an accident, which could result in serious injury or death. Always replace tires when the tread depth measures 1/8” (3 mm) or less. Improper tire inflation or the use of non-standard size or type of tires may adversely affect vehicle handling, which could result in vehicle damage or personal injury. Always maintain proper tire pressure.
MAINTENANCE Tires Wheel Removal 1. 2. 3. 4. Position the vehicle on a level surface. Place the transmission in PARK. Stop the engine. Loosen the wheel nuts slightly. Elevate the side of the vehicle by placing a suitable stand under the frame. 5. Remove the wheel nuts and washers. Remove the wheel. Wheel Installation 1. Place the transmission in PARK. 2. Place the wheel on the hub with the valve stem toward the outside and rotation arrows on the tire pointing toward forward rotation.
MAINTENANCE Lights Headlight and taillight lenses become dirty during normal operation. Clean all lights frequently to ensure a clear field of vision as well as visibility to other vehicles. When servicing a halogen lamp, don't touch the lamp with bare fingers. Oil from your skin leaves a residue, causing a hot spot that will shorten the life of the lamp. LED Headlamps (if equipped) If a headlight becomes damaged or inoperable, the entire headlight assembly must be replaced.
MAINTENANCE Lights Headlight Beam Adjustment X 25 ft. (7.6 m) X 8" (20 cm) 1. Place the vehicle on a level surface with the headlight approximately 25 ft. (7.6 m) from a wall. Place the transmission in PARK. 2. Measure the distance from the floor to the center of the headlight and make a mark on the wall at the same height. 3. Apply the brakes. Turn the ignition switch to the LIGHTS ON position. 4. Observe the headlight aim.
MAINTENANCE Lights Brake Lights When the brake pedal is depressed, the brake light comes on. Check the brake light before each ride. 1. Turn the ignition switch to the LIGHTS ON position. 2. Apply the brakes. The brake light should come on after about 10 mm (0.4 in.) of pedal travel. If the light doesn't come on, check the bulb. Vehicle Immersion NOTICE: If your vehicle becomes immersed, major engine damage can result if the machine is not thoroughly inspected.
MAINTENANCE Battery WARNING Battery electrolyte is poisonous. It contains sulfuric acid. Serious burns can result from contact with skin, eyes or clothing. Antidote: External: Flush with water. Internal: Drink large quantities of water or milk. Follow with milk of magnesia, beaten egg, or vegetable oil. Call physician immediately. Eyes: Flush with water for 15 minutes and get prompt medical attention. Batteries produce explosive gases. Keep sparks, flame, cigarettes, etc. away.
MAINTENANCE Battery WARNING Improperly connecting or disconnecting battery cables can result in an explosion and cause serious injury or death. When removing the battery, always disconnect the negative (black) cable first. When reinstalling the battery, always connect the negative (black) cable last. Battery Removal 1. Remove the seat. See page 28. 2. Remove the three (3) bolts securing the cup holder panel to the frame. Lift the panel to access the battery. 3.
MAINTENANCE Battery Battery Installation Using a new battery that has not been fully charged can damage the battery and result in a shorter life. It can also hinder vehicle performance. Follow the battery charging instructions on page 124 before installing the battery. An optional extreme use battery may be available for your model.
MAINTENANCE Battery Battery Storage Whenever the vehicle is not used for a period of three months or more, remove the battery from the vehicle, ensure that it's fully charged, and store it out of the sun in a cool, dry place. Check battery voltage each month during storage and recharge as needed to maintain a full charge. See page 124. Tip: Battery charge can be maintained by using a POLARIS Battery Tender charger or by charging about once a month to make up for normal selfdischarge.
MAINTENANCE Battery Battery Charging (Conventional Battery) 1. Remove the battery from the vehicle to prevent damage from leaking or spilled electrolyte during charging. See page 121. 2. Charge the battery with a charging output no larger than 1/10 of the battery’s amp/hr rating. Charge as needed to raise the specific gravity to 1.270 or greater. 3. Reinstall the battery. See page 122. Make sure the positive terminal is toward the front of the vehicle.
MAINTENANCE Battery Battery Charging (Sealed Battery) Always verify battery condition before and 1-2 hours after the end of charging. Charge Time State of Charge Voltage Action (Using constant current charger @ standard amps specified on top of battery) 100% 12.8-13.0 volts None required 75%-100% 12.5-12.8 volts 50%-75% 25%-50% 12.0-12.5 volts 11.5-12.0 volts None, check at 3 mos.
MAINTENANCE Cleaning and Storage Washing the Vehicle Keeping your POLARIS vehicle clean will not only improve its appearance but it can also extend the life of various components. PVT Intake Pre-Filter NOTICE: Water in the PVT system could cause the drive belt to become wet and slip in the clutches. Always avoid spraying water directly toward any intake pre-filters. High water pressure may damage the radiator fins and impair the radiator’s effectiveness.
MAINTENANCE Cleaning and Storage Washing the Vehicle If a high pressure water system is used for cleaning (not recommended), exercise extreme caution. The water may damage components and could remove paint and labels.
MAINTENANCE Cleaning and Storage Chrome Wheel Care (if equipped) Proper maintenance will protect chrome wheels from corrosion, preserve wheel life and ensure a “like new” appearance for many years. Tip: Chrome wheels exposed to road salt (or salt in the air in coastal areas) are more susceptible to corrosion if not properly cleaned. Clean chrome wheels more often if they're exposed to salt or other corrosive elements. 1. Wash chrome wheels frequently. Use a mild detergent.
MAINTENANCE Cleaning and Storage Storage Tips NOTICE: Starting the engine during the storage period will disturb the protective film created by fogging and damage could occur. Never start the engine during the storage period. Clean the Exterior Make any necessary repairs and clean the vehicle as recommended. See page 126. Stabilize the Fuel 1. Fill the fuel tank. 2. Add POLARIS Carbon Clean Fuel Treatment or POLARIS Fuel Stabilizer or equivalent fuel treatments or stabilizers.
MAINTENANCE Cleaning and Storage Storage Tips Inspect and Lubricate Inspect all cables and lubricate all areas of the vehicle as recommended in the Periodic Maintenance Chart beginning on page 81. Fog the Engine 1. Treat the fuel system with POLARIS Carbon Clean or other equivalent fuel treatment. Follow the instructions on the container. Start the engine. Allow it to idle for several minutes so the Carbon Clean reaches the injectors. Stop the engine. 2.
MAINTENANCE Cleaning and Storage Removal from Storage 1. Check the battery electrolyte level and charge the battery if necessary. Install it in the vehicle. Make sure the battery vent hose is routed properly and that it's not pinched or restricted in any way. 2. Make sure the spark plug is tight. 3. Fill the fuel tank with fuel. 4. Check all the points listed in the Daily Pre-Ride Inspection section on page 51.
SPECIFICATIONS ACE / ACE 570 Gross Vehicle Weight Dry Weight Test GVW - Rollover Protection System (ROPS) Front Rack/Box Capacity Rear Rack/Box Capacity Maximum Weight Capacity (Payload) Receiver Hitch Tongue Capacity Receiver Hitch Towing Capacity Fuel Capacity Engine Oil Capacity Coolant System Capacity Coolant Bottle Capacity Demand Drive Fluid Capacity Transmission Oil Capacity Overall Length/Width/Height Wheelbase Ground Clearance Engine Displacement Bore x Stroke Alternator Output Compression Ratio St
SPECIFICATIONS ACE / ACE 570 Lubrication System Engine Oil Driving System Type Shift Type Gear Reduction - Low Gear Reduction - Reverse Gear Reduction - High Drive Ratio - Front Tire Size - Front Tire Size - Rear Tire Pressure Brakes, Park Brakes, Front/Rear Headlights Taillights Brake Lights Instrument Cluster Auxiliary DC Outlet Wet Sump PS-4 5W-50 Automatic POLARIS Variable Transmission Side Lever (H/L/N/R/P) 28.84:1 25.83:1 9.65:1 2.
POLARIS PRODUCTS Part Number 2870791 2876244 2876245 2878068 2878069 2870465 2877922 2877923 2880514 2880513 2871312 2871322 2871423 2871460 2871515 2871551 2871329 2871326 2870652 2872189 2871956 2859044 134 Description Engine Lubricant Fogging Oil (12 oz./355 ml Aerosol) PS-4 Full Synthetic 5W-50 4-Cycle Oil (qt./.95 l) PS-4 Full Synthetic 5W-50 4-Cycle Oil (gal./3.8 l) Gearcase / Transmission Lubricants AGL Full Synthetic Gearcase Lubricant & Transmission Fluid (qt./.
TROUBLESHOOTING Drive Belt Wear/Burn Possible Cause Driving onto a pickup or tall trailer in high range Starting out going up a steep incline Driving at low RPM or ground speed (3-7 MPH) Insufficient warm-up at low ambient temperatures Slow/easy clutch engagement Towing/pushing at low RPM/low ground speed Utility use/plowing Stuck in mud or snow Climbing over large objects from a stopped position Belt slippage from water or snow ingestion into the PVT system Clutch malfunction Poor engine performance Slipp
TROUBLESHOOTING Engine Doesn't Turn Over Possible Cause Low battery voltage Loose battery connections Loose solenoid connections Loose electronic control box connections Solution Recharge the battery to 12.
TROUBLESHOOTING Engine Pings or Knocks Possible Cause Poor quality or low octane fuel Incorrect ignition timing Incorrect spark plug gap or heat range Solution Replace with recommended fuel Your POLARIS dealer can assist.
TROUBLESHOOTING Engine Stops or Loses Power Possible Cause Out of fuel Kinked or plugged fuel vent line Water is present in fuel Fouled or defective spark plug Worn or defective spark plug wires Incorrect spark plug gap or heat range Loose ignition connections Low battery voltage Incorrect fuel Clogged air filter Other mechanical failure Overheated engine 138 Solution Refuel Inspect and replace Replace with new fuel Inspect, clean and/or replace spark plug Your POLARIS dealer can assist.
WARRANTY Limited Warranty POLARIS Industries Inc., 2100 Highway 55, Medina, MN 55340 (POLARIS) gives a SIX MONTH LIMITED WARRANTY on all components of your POLARIS vehicle against defects in material or workmanship. POLARIS further warrants that the spark arrester in this product will meet the efficiency requirements of USFS standard 5100-1C for at least 1000 hours when subjected to normal use and when maintenance and installation are in accordance with POLARIS recommendations.
WARRANTY Warranty Coverage And Exclusions: Limitations Of Warranties And Remedies This warranty excludes damages or failures caused by abuse, accident, fire, or any other cause other than a defect in materials or workmanship and provides no coverage for consumable components, general wear items, or any parts exposed to friction surfaces, stresses, environmental conditions and/or contamination for which they were not designed or not intended, including but not limited to the following items: • • • • • • • •
WARRANTY How To Obtain Warranty Service If your vehicle requires warranty service, you must take it to a POLARIS Servicing Dealer. When requesting warranty service you must present your copy of the Warranty Registration Form to the dealer. (THE COST OF TRANSPORTATION TO AND FROM THE DEALER IS YOUR RESPONSIBILITY.) POLARIS suggests that you use your original selling dealer; however, you may use any POLARIS Servicing Dealer to perform warranty service.
WARRANTY Notice If your product is registered outside of the country where it was purchased and you have not followed the procedure set above, your product will no longer be eligible for warranty or service bulletin coverage of any kind, other than safety bulletins. Products registered to government officials or military personnel on assignment outside of the country where the product was purchased will continue to be covered by the Limited Warranty.
WARRANTY U.S.A. EPA Emissions Limited Warranty This emissions limited warranty is in addition to the POLARIS standard limited warranty for your vehicle. POLARIS Industries Inc. warrants that at the time it is first purchased, this emissions-certified vehicle is designed, built and equipped so it conforms with applicable U.S. Environmental Protection Agency emission regulations.
WARRANTY U.S.A.
WARRANTY U.S.A. EPA Emissions Limited Warranty Owners are responsible for performing the scheduled maintenance identified in the owner's manual. POLARIS may deny warranty claims for failures that have been caused by the owner's or operator's improper maintenance or use, by accidents for which POLARIS has no responsibility, or by acts of God. Any qualified repair shop or person may maintain, replace, or repair the emission control devices or systems on your vehicle.
MAINTENANCE LOG Use the following chart to record periodic maintenance.
INDEX A C Access Panels . . . . . . . . . . . . . . . . . . 25 Accessory Outlet. . . . . . . . . . . . . . . . 31 Adding Coolant. . . . . . . . . . . . . . . . 100 Adjustment Seat. . . . . . . . . . . . . . . . . . . . . . . . 28 Steering Wheel . . . . . . . . . . . . . . . 26 Adjustment, Headlight Beam . . . . . 118 Adjustment, Throttle Freeplay . . . . 110 Age Restrictions . . . . . . . . . . . . . . . . 14 Air Filter . . . . . . . . . . . . . . . . . . . . . 106 Air Filter Cleaning . . . . . . . . . .
INDEX E F Emission Control, Noise . . . . . . . . . 80 Emissions Limited Warranty . . 143-145 Engaging AWD . . . . . . . . . . . . . . . . 35 Engine Break-In. . . . . . . . . . . . . . . . 50 Engine Fogging . . . . . . . . . . . . . . . 130 Engine Intake Pre-Filter. . . . . . . . . 107 Engine Oil . . . . . . . . . . . . . . . . . . 87-93 Engine Starting . . . . . . . . . . . . . . . . 54 Engine Stopping. . . . . . . . . . . . . . . . 55 Equipment Modifications . . . . . . . . 23 Error Codes, Engine. . . .
INDEX K O Key, Periodic Maintenance Chart . . . 82 Oil Recommendations . . . . . . . . . . . 87 Operation on Public Lands . . . . . . . . 80 Operation, Cooling System. . . . . . . 100 Operation, Transmission. . . . . 103-105 Operator Restrictions . . . . . . . . . . . . 14 L Light Switch . . . . . . . . . . . . . . . . . . . 31 Lights . . . . . . . . . . . . . . . . . . . 117-119 Beam Adjustment. . . . . . . . . . . . 118 Brake Lights. . . . . . . . . . . . . . . . 119 Headlight Lamp Replacement . .
INDEX S T Safe Operation Practices . . . . . . . 52-53 Safety Labels . . . . . . . . . . . . . . . . 10-13 Safety Symbols . . . . . . . . . . . . . . . . . 4 Safety Training . . . . . . . . . . . . . . . . . 7 Safety Training, ROHVA . . . . . 52, 56 Safety Warnings. . . . . . . . . . . . . . 14-23 Safety, Winch Maintenance. . . . . . . 79 Seat Adjustment. . . . . . . . . . . . . . . . 28 Seat Belt. . . . . . . . . . . . . . . . . . . . . . 29 Seat Removal . . . . . . . . . . . . . . . . . .
PMS 419 WARNING Improper vehicle use can result in SEVERE INJURY or DEATH NEVER Operate: • If you are under age 16 and without a valid driver’s license. • Without first viewing safety video and taking a ROHVA training course at www.rohva.org. • On excessively steep hills. • On public roads (unless designated for off-road use). • On paved surfaces - pavement may seriously affect handling and control. • With non-Polaris approved accessories - they may seriously affect stability.
