WELCOME Thank you for purchasing a Polaris vehicle, and welcome to our worldwide family of Polaris owners. We proudly produce an exciting line of utility and recreational products. • Snowmobiles • All-terrain vehicles (ATVs) • Quadricycles/Tractors • RANGER utility vehicles • Victory motorcycles Always follow the instructions and recommendations in this manual.
POLARIS and POLARIS THE WAY OUT are registered trademarks of Polaris Industries Inc. Copyright 2008 Polaris Sales Inc. All information contained within this publication is based on the latest product information at the time of publication. Due to constant improvements in the design and quality of production components, some minor discrepancies may result between the actual vehicle and the information presented in this publication.
TABLE OF CONTENTS Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Features and Controls . . . . . . . . . . . . . . . . . . . 20 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 Emission Control Systems . . . . . . . . . . . . . . . 60 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . 61 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . 116 Polaris Products.
INTRODUCTION 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. WARNING A WARNING indicates a hazardous situation which, if not avoided, may result in death or serious injury.
INTRODUCTION WARNING Failure to follow the warnings in this manual can result in serious injury or death. A Polaris Tractor is not a toy and can be hazardous to operate. A collision or rollover can occur quickly, even during routine maneuvers, if you fail to take proper precautions. • Read this owner’s manual. Understand all safety warnings, precautions and operating procedures before operating a Polaris Tractor. • Never operate this vehicle without proper instruction. Take a training course.
INTRODUCTION Vehicle Identification Numbers Record your vehicle's identification numbers and key number in the spaces provided. Remove the spare key and store it in a safe place. An ignition key can be duplicated only by ordering a Polaris key blank (using your key number) and mating it with one of your existing keys. The ignition switch must be replaced if all keys are lost.
Safety Training SAFETY When you purchased your new Tractor, your dealer offered a hands-on safety training course. You were also provided with printed materials that explain safe operating procedures. Review this information on a regular basis. If you purchased a used Polaris Tractor from a party other than a Polaris dealer, please request free safety training from any authorized Polaris dealer.
SAFETY Safe Riding Gear Always wear protective clothing to reduce the chance of injury. Eye Protection Helmet Long Sleeves Gloves Long Pants Boots Helmet Always wear a helmet that meets or exceeds established safety standards. Approved helmets in the USA and Canada bear a U.S. Department of Transportation (DOT) label. Approved helmets in Europe, Asia and Oceania bear the ECE 22.05 label.
Safe Riding Gear SAFETY Eye Protection Do not depend on eyeglasses or sunglasses for eye protection. Whenever riding a Polaris vehicle, always wear shatterproof goggles or use a shatterproof helmet face shield. Polaris recommends wearing approved Personal Protective Equipment (PPE) bearing markings such as VESC 8, V-8, Z87.1, or CE. Make sure protective eye wear is kept clean. Gloves Off-road style gloves with knuckle pads are the best for comfort and protection.
SAFETY Rider Safety WARNING Serious injury or death can result if you do not follow the instructions and procedures listed here and throughout this manual. Read and understand all warnings, cautions and operating procedures in this manual and on the safety labels before operating the Tractor. Never operate a Tractor without proper instruction. Take a training course. Beginners should receive training from a certified instructor.
Rider Safety SAFETY Never carry a passenger on this vehicle. Always wear an approved helmet that fits properly. Wear eye protection (goggles or face shield), gloves, boots, long sleeves and long pants. Never consume alcohol or drugs before or while operating a Tractor. Never operate at excessive speeds. Travel and turn at speeds appropriate for the terrain, visibility, operating conditions and your experience.
SAFETY Rider Safety Always inspect your Tractor before each use to verify that it's in safe operating condition. Follow the inspection and maintenance procedures outlined in this manual. See page 41. Keep both hands on the handlebars. Keep both feet on the footrests. Always travel slowly when operating on unfamiliar terrain. Use extra caution. Always follow the procedures outlined in this manual for turning. See page 45. Never turn sharply at excessive speeds, which can lead to vehicle overturn.
Rider Safety SAFETY Never attempt jumps or other stunts. Always follow the procedures outlined in this manual for driving on hills. See page 46. Never operate on hills too steep for the Tractor or for your abilities. Practice on smaller hills before attempting larger hills. Avoid climbing hills steeper than 25°. Always move the 4X4 switch to ADC 4X4 before ascending or descending a hill. Always follow the procedures outlined in this manual for driving downhill and for braking on hills. See page 49.
SAFETY Rider Safety Always follow the procedures outlined in this manual for braking if you stall or roll backwards while climbing a hill. Never back down a hill. See page 50. Always follow the procedures outlined in this manual for operating over obstacles. See page 55. Always follow the procedures outlined in this manual for operating on slippery or loose surfaces. Use extra caution. Always avoid skidding or sliding. See page 54.
Rider Safety SAFETY Always follow the procedures outlined in this manual for driving in reverse. See page 56. Always use the size and type of tires specified for your vehicle. Maintain the proper tire pressure. Never modify a Tractor through improper installation or use of accessories. Never exceed the stated load capacity for your vehicle. Cargo must be properly distributed and securely attached. Reduce speed and follow the instructions in this manual for carrying cargo or towing.
SAFETY Rider Safety Never operate the Tractor on a frozen body of water. Operating on paved surfaces may affect the handling and control of the Tractor and could result in loss of control. Avoid sudden turns or swift movement of the handlebars. Always remove the ignition key when the vehicle is not in use to prevent unauthorized use or accidental starting. Always unlock the steering before starting the engine. See page 26. Hot components can cause serious burns and fire.
SAFETY Safety Labels and Locations Warning labels have been placed on the vehicle for your protection. Read and follow the instructions on each label carefully. If a label becomes illegible or comes off, contact your Polaris dealer to purchase a replacement. Replacement safety labels are provided by Polaris at no charge. The part number is printed on the label. The following pages repeat the information found on each label.
SAFETY Safety Labels and Locations Reverse Override Alert Rack Warning + + Clutch Cover Alert + ++ + Rack Warning “No Passenger” Warning Tire Pressure/ Load Alert Tire Pressure/Load Alert TIRE PRESSURE IN PSI (kPa): FRONT 5 (34.5) REAR 5 (34.5) MAXIMUM WEIGHT CAPACITY 420 LBS. (191 kg) INCLUDES WEIGHT OF OPERATOR, CARGO AND ACCESSORIES. Read Owner's Manual for more detailed loading information.
Safety Labels and Locations SAFETY “No Passenger” Warning WARNING NEVER ride as a passenger. Passengers can cause a loss of control, resulting in SEVERE INJURY or DEATH. 7175378 Clutch Cover Alert NO STEP 7173030 Rack Warning WARNING • DO NOT TOW FROM RACK OR BUMPER. Vehicle damage or tipover may result causing severe injury or death. Tow only from tow hooks or hitch. • Max. Rack Loads: Front 90 lbs. (41 kg) Rear 180 lbs.
FEATURES AND CONTROLS Switches Mode/Reverse Override Switch Engine Stop Switch Hazard Switch Master Light Switch Headlight Switch Horn Switch Turn Signal Switch 4X4 Switch Main Key Switch Master Light Switch The master light switch must be in the ON position to allow operation of the headlights, parking lights and taillights. Mode/Reverse Override Switch Press the switch to toggle through the speedometer display modes (except in reverse). See page 31.
Switches FEATURES AND CONTROLS Main Key Switch End all electrical power to the vehicle. The LIGHTS ON position turns the headlights on. The master light switch must be on and the engine stop switch must be in the RUN position. Start the engine. The headlights are not on in this position. After starting the engine, release the key switch to the PARKING LIGHTS ON position. The headlights and taillights are on in this position. Do not attach a large key fob or key ring to the main switch.
FEATURES AND CONTROLS Switches 4X4 Switch Use the 4X4 switch to engage ADC 4X4, 4X4 or 2X4. See page 28. Hazard Warning Switch Push the hazard warning switch to cause all turn signal lights to flash simultaneously. Use this feature to alert others of an emergency or other situation requiring caution. 4X4 Switch Hazard Warning Switch Turn Indicators Turn Signal Switch Push the toggle switch either left or right to activate the corresponding turn signal light. The indicator on the pod will also flash.
Mirrors FEATURES AND CONTROLS Use the mirrors to assist in traffic maneuvers. Always check and adjust the mirrors before driving the Tractor. Throttle Lever Failure to check or maintain proper operation of the throttle system can result in an accident if the throttle lever sticks during operation. Check the lever for proper operation before starting the engine. Check occasionally during operation. Do not start or operate a Tractor with sticking or improperly operating throttle controls.
FEATURES AND CONTROLS Brakes Aggressively applying the brakes when backing down a hill may cause rear tipover. Aggressively applying the brakes while moving forward may cause the rear wheels to skid and result in loss of control. Read this owner's manual and understand the operation of all brake systems on this vehicle. Always use caution whenever applying the brakes. Foot Brake The all-wheel foot brake is located on the right footrest. The foot brake operates both front and rear brakes.
FEATURES AND CONTROLS Seat Load Adjuster Seat Load Adjustment Adjust the seat spring for the comfort of a lighter or heavier operator. Reach under the rear rack to access the adjuster. Tighten the spring for heavier riders. Loosen the spring for lighter riders. Use the following table to determine the best preload measurement for rider weight. Measure preload between the adjuster plate and the lower spring retainer.
FEATURES AND CONTROLS Steering Lock Lock the steering to prevent unauthorized use or theft of the vehicle. The handlebars are locked in the fully turned position when the steering is locked. Always unlock the steering before starting the engine. 1. Turn the handlebars to the full right position. The handlebars may also be locked in the full left position. 2. Insert the steering lock key and turn it clockwise. Remove the key. 3. Place the steering lock keys in a safe place.
Hitches FEATURES AND CONTROLS Hitch Installation/Removal 1. Release the wire lock from the 12.7 mm pin and remove the pin. 2. Install the hitch to the receiver. 3. Install the 12.7 mm pin through the bore of both the receiver and the hitch. Secure the wire lock. Make sure the hitch assembly is secure at that the wire lock is properly engaged over the pin. 4. To remove the hitch, release the wire lock, remove the hitch, reinstall the pin to the receiver and secure the wire lock.
FEATURES AND CONTROLS All Wheel Drive (4X4) System The All Wheel Drive system is controlled by the 4X4 switch. ADC 4X4 When the switch is on ADC 4X4, the ADC system allows engine braking to all four wheels when the vehicle descends a hill or incline. Always move the 4X4 switch to ADC 4X4 before ascending or descending a hill. See page 30. 4X4 When the switch is on 4X4, the vehicle is in 4X4, and the 4X4 indicator light in the instrument cluster will be on.
FEATURES AND CONTROLS All Wheel Drive (4X4) System Engaging 4X4 The 4X4 switch may be turned on or off while the vehicle is moving. 4X4 will not engage until engine speed is below 3100 RPM. 4X4 remains engaged until the switch is turned off. There is no limit to the length of time the vehicle may remain in 4X4. If the switch is turned off while the demand drive unit is engaged, it will not disengage until the rear wheels regain traction.
FEATURES AND CONTROLS Active Descent Control (ADC) System The ADC system allows engine braking to all four wheels when the vehicle descends a hill or incline. Always move the 4X4 switch to ADC 4X4 before ascending or descending a hill.
FEATURES AND CONTROLS Instrument Cluster The instrument cluster senses vehicle speed from the transmission. In addition to showing vehicle speed, the speedometer needle flashes when a warning condition exists. The instrument cluster measures distance in miles or kilometers, as well as hours of operation. It also includes a reverse speed limiter function that limits the vehicle's speed to approximately 11-14 km/h. Refer to page 20 for additional information.
FEATURES AND CONTROLS Instrument Cluster Rider Information Center The rider information center is located in the instrument cluster. All segments will light up for 2.5 seconds at start-up. If the instrument cluster fails to illuminate, a battery over-voltage may have occurred and the instrument cluster may have shut off to protect the electronic speedometer. If this occurs, take the vehicle to your Polaris dealer for proper diagnosis. 1.
FEATURES AND CONTROLS Instrument Cluster Rider Information Center Standard Modes Use the MODE button to toggle through the mode options. The reverse override button is also the MODE button. See page 20. The transmission cannot be in reverse when using this feature. Odometer Mode The odometer records the miles or kilometers traveled by the Tractor. Trip Meter Mode The trip meter records the miles or kilometers traveled by the Tractor on each trip if it's reset before each trip.
FEATURES AND CONTROLS Instrument Cluster Rider Information Center Diagnostic Mode The wrench icon will display when the gauge is in the diagnostic mode. To exit the diagnostic mode, turn the key switch off and on. Any movement of the tires will also cause the gauge to exit the diagnostic mode. To enter the diagnostics mode: 1. Turn the key switch off and wait 10 seconds. 2. Lock the parking brake. 3. Place the transmission in neutral. 4. Hold the mode/reverse override button and turn the key switch on.
FEATURES AND CONTROLS Instrument Cluster Rider Information Center Diagnostic Mode Battery Voltage Screen View this screen to check battery voltage level. Tachometer Screen View the tachometer to check engine speed. 4X4 Diagnostic Screen The gauge indicates whether or not current is flowing through the 4X4 coil (only on models with switchable 4X4). This screen is for informational purposes only. Please see your dealer for all major repairs.
FEATURES AND CONTROLS Instrument Cluster Rider Information Center Diagnostic Mode Programmable service interval To enable or disable the service interval: 1. Enter the diagnostic mode. 2. Toggle to the service interval screen. 3. Press and hold the mode button for about 7 seconds, until either ON or OFF appears in the Rider Information Center, depending on your preference. To reset the service interval: 1. Enter the diagnostic mode. 2. Toggle to the service interval screen. 3.
FEATURES AND CONTROLS Instrument Cluster Rider Information Center Diagnostic Mode Miles/Kilometers toggle The display in the tripmeter and odometer can be changed to display either standard or metric units of measurement. 1. Enter the diagnostic mode. 2. Toggle to the screen that displays either kilometers (KM) or miles (MP). 3. Press and hold the mode button until the letters flash, then press and release the button once. When the display stops flashing, the mode has been set.
FEATURES AND CONTROLS Instrument Cluster Rider Information Center Downloading Codes 3. The Check Engine icon will blink once, pause, then blink twice (blink code 12) to begin the diagnostic sequence. The EFI module is now searching for blink codes. If a code exists, the Check Engine icon will flash the code. 4. Count the number of times the Check Engine icon flashes.
FEATURES AND CONTROLS Instrument Cluster Rider Information Center Downloading Codes Blink Code 12 22 22 25 31 31 36 36 37 37 41 41 42 42 44 45 46 47 47 51 51 52 52 55 55 56 56 58 58 59 59 63 63 72 73 73 61 Failure Description BEGIN SEQUENCE Throttle Position Sensor Low Throttle Position Sensor High Gear Sensor Signal System Voltage Low System Voltage High Ignition Coil A Prim/Sec Circuit Malfunction: Open Load/Short-to-Ground Ignition Coil A Prim/Sec Circuit Malfunction: Shorted Load/Short-to-Battery Ign
OPERATION Break-In Period The break-in period for your new Polaris Tractor is the first ten hours of operation, or the time it takes to use the first two full tanks of gasoline. No single action on your part will increase the life and performance of your Tractor more than following the procedures for a proper break-in. Careful treatment of a new engine and drive components will result in more efficient performance and longer life for these components.
OPERATION Pre-Ride Checklist Item Remarks Page Hand brake/lever travel Ensure proper operation 83 Foot brake Ensure proper operation 83 Brake fluid Ensure proper level 83 Front suspension Inspect, lubricate if necessary 65 Rear suspension Inspect, lubricate if necessary 65 Steering/steering lock Unlock the steering; ensure free operation 26 Steering Ensure free operation Tires Inspect condition and pressure 88 - Wheels/fasteners Inspect, ensure fastener tightness 88 89 Frame n
OPERATION Starting the Engine NOTICE: Operating the vehicle immediately after starting could cause engine damage. Allow the engine to warm up for several minutes before operating. 1. Position the vehicle on a level surface. 2. Place the transmission in PARK (or neutral). 3. Sit on the vehicle. 4. Apply the brakes. 5. Move the engine stop switch to RUN. 6. Do not press the throttle while starting the engine. 7. Turn the ignition key past the PARKING LIGHTS ON position to engage the starter.
Cold Weather Operation OPERATION Internal engine condensation increases as outside temperatures decrease. If the vehicle is used year-round, check the oil level frequently. A rising oil level could indicate condensation in the bottom of the oil tank, which can lead to engine damage. Any condensation must be drained. Always operate the engine long enough to reach operating temperature, which reduces condensation.
OPERATION Driving Procedures 1. Wear protective riding gear. See page 8. 2. Perform the pre-ride inspection. See page 41. 3. Sit upright. Keep your feet on the footrests. Keep both hands on the handlebars. 4. Start the engine and allow it to warm up. 5. Apply the brakes. 6. Shift the transmission into gear. 7. Check your surroundings and determine your path of travel. 8. Release the brakes. 9. Slowly squeeze the throttle lever toward the handlebar to begin driving. 10. Drive slowly.
Turning the Vehicle OPERATION 1. Before turning, activate a turn signal to alert others of your intentions. Activate the left signal before a left turn. Activate the right signal before a right turn. 2. Steer in the direction of the turn, leaning your upper body to the inside of the turn while supporting your weight on the outer footrest. Use the same leaning technique for turning in reverse. 3. Never turn quickly when carrying cargo. 4.
OPERATION Driving Uphill 25° Maximum Whenever traveling uphill, follow these precautions: 1. Always move the 4X4 switch to ADC 4X4 before ascending or descending a hill. See page 30. 2. Avoid steep hills (25° maximum). 3. Avoid hills with slippery or loose surfaces. 4. Keep both feet on the footrests. 5. Shift body weight uphill. 6. Drive straight uphill. 7. Proceed at a steady rate of speed to avoid stalling. 8. Be alert. Be prepared to take emergency action. This may include dismounting quickly. 9.
Driving Uphill OPERATION If all forward speed is lost: Keep your weight uphill. If the vehicle begins rolling downhill, never apply engine power. Never apply the brakes aggressively while rolling backwards. 1. Apply the brakes gradually. 2. When fully stopped, lock the hydraulic parking brake. 3. Dismount on the uphill side, or on the left side if the vehicle is pointed straight uphill. 4. Use the K-turn to turn around. See page 50. Always follow the procedures outlined in this manual for climbing hills.
OPERATION Driving on a Sidehill (Sidehilling) Avoid crossing the side of a hill (sidehilling) if possible. If sidehilling is necessary, follow these precautions: 1. Slow down. 2. Avoid hills with slippery or loose surfaces. 3. Avoid crossing the sides of steep hills. 4. Shift your weight uphill. 5. Keep your feet on the footrests. 6.
Driving Downhill OPERATION When driving downhill, follow these precautions: 1. Always move the 4X4 switch to ADC 4X4 before ascending or descending a hill. See page 30. 2. Avoid steep hills (25° maximum). 3. Avoid hills with slippery or loose surfaces. 4. Never drive downhill at high speed. Slow down. 5. Drive straight downhill. Avoid driving downhill at an angle, which can cause the vehicle to pitch sharply to one side. 6. Shift your weight rearward. 7. Apply the brakes slightly to aid in slowing.
OPERATION Turning Around on a Hill (K-Turn) If the vehicle stalls while climbing a hill, never back it down the hill! Use the K-turn to turn around. 2.4 m 1. Stop the vehicle. Keep your weight uphill. 2. Always move the 4X4 switch to ADC 4X4 before ascending or descending a hill. See page 30. 3. Lock the hydraulic parking brake. 4. Leave the transmission in forward gear. Turn the engine off. 5. Dismount on the uphill side, or on the left side if the vehicle is pointed straight uphill. 6.
Turning Around on a Hill (K-Turn) 9. 10. 11. 12. 13. 14. OPERATION Lock the hydraulic parking brake. Remount from the uphill side. Keep your weight uphill. Apply the foot brake. With the transmission still in forward, start the engine. Squeeze and release the brake lever to release the parking brake. Release the foot brake and drive slowly downhill. Control speed with either the hand or foot brake until the vehicle is on level ground.
OPERATION Driving Through Water Maximum Depth Follow these procedures when driving through water: 1. Check water depth and current before crossing. 2. Choose a crossing where both banks have gradual inclines. 3. Drive slowly. Avoid rocks and obstacles. 4. Avoid operating in water deeper than the bottom of the footrests. If it's unavoidable, travel slowly, balance your weight carefully and avoid sudden movements. Maintain a slow and steady forward motion.
Driving Through Water OPERATION If your vehicle becomes fully immersed, and it's impossible to take it to a dealer before starting it, follow the steps described on page 98. Have the vehicle serviced by your dealer promptly. Always follow the procedures outlined in this manual for driving through water. Never drive through deep or fast-flowing water. If the vehicle stops while fully submerged, major engine damage can result if the machine is not thoroughly inspected.
OPERATION Driving on Slippery Surfaces Sideways skid Turn in direction of skid Always follow the procedures outlined in this manual for operating on slippery or loose surfaces. Use extra caution. Always avoid skidding or sliding. Whenever driving on slippery or loose surfaces such as wet trails, gravel, snow or ice, follow these precautions: 1. Slow down before driving onto slippery surfaces. 2. Engage 4X4 before wheels begin to lose traction. 3. Be alert. Watch the trail. 4. Avoid quick, sharp turns.
Driving Over Obstacles 1. 2. 3. 4. OPERATION Always check for obstacles before operating in a new area. Be alert. Watch the terrain. Use extra caution. Never operate over large obstacles. Avoid hazards such as logs, rocks and low branches. Parking on an Incline Avoid parking on an incline. If it's unavoidable, follow these precautions: 1. Stop the engine. 2. Place the transmission in PARK. 3. Always block the rear wheels on the downhill side.
OPERATION Driving in Reverse Follow these precautions when operating in reverse: 1. Always check for obstacles or people behind the vehicle before backing. 2. Avoid backing downhill. 3. Drive slowly. Apply the brakes lightly for stopping. 4. Avoid turning at sharp angles. 5. Never open the throttle suddenly. 6. Do not use the override switch unless additional power is required for vehicle movement. Use with caution.
Hauling Cargo OPERATION 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. • Read and understand the load distribution warnings listed on the vehicle warning labels. • NEVER EXCEED THE MAXIMUM WEIGHT CAPACITY of the vehicle.
OPERATION Hauling Cargo Always read and understand the load distribution warning labels on the vehicle. Never exceed the weight capacities specified for this vehicle. 2/3 1/3 Towing Loads Towing is approved OFF-ROAD ONLY. Operating a Tractor/trailer combination on public roads is prohibited. See your Polaris dealer about configuring the vehicle to be certified to tow a trailer on-road. Do not tow any trailer on a grade steeper than 15°. • Use the front hitch for vehicle recovery or towing only.
Hauling Cargo OPERATION Towing Loads Using an improper hitch or exceeding the maximum tongue weight capacity can result in serious damage to the vehicle and will void your warranty. Never install a hitch longer than 10 cm. Never install automotive accessories on your Polaris Tractor. Always install Polaris-approved (or equivalent) accessories designed for Tractor use.
EMISSION CONTROL SYSTEMS Noise Emission Control System Do not modify the engine, intake or exhaust components, as doing so may affect compliance with governmental noise level requirements. Spark Arrestor Your Polaris vehicle has a spark arrestor that was designed for on-road and off-road operation. It is required that this spark arrestor remain installed and functional when the vehicle is operated. Exhaust Emission Control System Exhaust emissions are controlled by engine design.
Periodic Maintenance Chart MAINTENANCE Maintenance intervals in the following chart are based upon average riding conditions. Vehicles subjected to severe use must be inspected and serviced more frequently. The programmable service interval mode on the instrument cluster will help determine when maintenance service is due. See page 31. Record maintenance and service in the Maintenance Log beginning on page 126. Service and adjustments are important for proper vehicle operation.
MAINTENANCE Periodic Maintenance Chart Improperly performing the procedures marked with a could result in component failure and lead to serious injury or death. Have an authorized Polaris dealer perform these services. Maintenance Chart Key X Perform these operations more often for vehicles subjected to severe use. E Emission-related service Q Have an authorized Polaris dealer perform these services. Perform all services at whichever maintenance interval is reached first.
Periodic Maintenance Chart Item Maintenance Interval X Brake pad wear Q Battery Remarks (whichever comes first) Hours Calendar X Air filter, E main element MAINTENANCE Kilometers - Weekly - Inspect; replace as needed 10 Monthly 160 Inspect periodically Check terminals; clean; test 20 Monthly 320 X Demand drive fluid 25 Monthly 400 Inspect level; change yearly X Rear gearcase oil (if equipped) 25 Monthly 400 Inspect level; change yearly X Transmission oil 25 Monthly 400 Insp
MAINTENANCE Periodic Maintenance Chart Item Maintenance Interval Remarks (whichever comes first) Hours Calendar Kilometers Q Valve clearance 100 12 M 1600 Inspect; adjust Q Fuel system 100 12 M 1600 Check for leaks at tank cap, lines, filter, pump; replace lines every 2 years X Radiator 100 12 M 1600 Inspect; clean external surfaces X Cooling hoses 100 12 M 1600 Inspect for leaks X Engine mounts 100 12 M 1600 Inspect 100 12 M 1600 Inspect Q Spark plug 100 12 M 1600 In
MAINTENANCE Lubrication Guide Check and lubricate all components at the intervals outlined in the Periodic Maintenance Chart beginning on page 61. Items not listed in the chart should be lubricated at the General Lubrication interval. The a-arms and upper control arms are lubricated at the factory, and no additional lubrication will be needed. However, if these components are subjected to severe use, grease zerks have been provided for additional lubrication at the user's discretion.
MAINTENANCE Engine Oil Oil Recommendations Always change the oil filter whenever changing oil. Polaris recommends the use of Polaris PS-4 PLUS Performance Synthetic 2W-50 4-cycle oil or a similar oil for this engine. Oil may need to be changed more frequently if Polaris oil is not used. Always use 2W-50 oil. Follow the manufacturer's recommendations for ambient temperature operation. NOTICE: Mixing brands or using a non-recommended oil may cause serious engine damage. Always use a recommended oil.
MAINTENANCE Engine Oil Oil Level 1. Position the vehicle on a level surface. 2. Place the transmission in PARK. 3. Start the engine. Allow it to idle for 30 seconds. 4. Stop the engine. 5. Remove the dipstick. Wipe it dry with a clean cloth. 6. Reinstall the dipstick completely. Dipstick 7. Remove the dipstick and check the oil level. Add oil as needed. Maintain the oil level in the safe range. Do not overfill. Safe Range { Add Oil Safe 8. Reinstall the dipstick.
MAINTENANCE Engine Oil Oil and Filter Change 1. Position the vehicle on a level surface. 2. Place the transmission in PARK. 3. Start the engine. Allow it to idle for 30 seconds. 4. Stop the engine. 5. Clean the area around the drain plug. 6. Place a drain pan under the oil tank. 7. Remove the drain plug. 8. Drain the oil. Drain Plug Screen Fitting New Sealing Washer Hot oil may result in serious burns. Do not allow hot oil to contact skin. 9. Clean the drain plug.
Engine Oil MAINTENANCE Oil and Filter Change 11. Disconnect the lower oil delivery hose and remove the screen fitting from the oil tank. Clean the fitting. Seal the fitting threads with LOCTITE PST 505 or PTFE seal tape. 12. Reinstall the screen fitting and rotate the fitting clockwise a minimum of 2 1/2 turns into the Alignment Mark tank threads. Continue to rotate the fitting until the nipple of the fitting aligns with the mark on the tank. Do not over-tighten.
MAINTENANCE Engine Oil Oil and Filter Change 20. Remove the dipstick. 21. Add 1.9 liters of recommended oil. TIP: If the sump is not drained, add about 1.6 liters initially. 22. Reinstall the dipstick. 23. Place the transmission in PARK. 24. Prime the oil pump using the procedure on page 71. 25. Stop the engine. Check for oil leaks. 70 Safe Range { 26. Check the oil level. Add oil as needed. Maintain the oil level in the safe range. Do not overfill. 27. Reinstall the dipstick. 28.
Engine Oil MAINTENANCE Oil and Filter Change Oil Pump Priming This priming procedure must be Tank performed whenever the oil hose 5 cm connection between the oil tank and pump inlet has been disconnected. 1. Clamp the vent line 5 cm from the oil tank, between the end of the oil tank vent fitting and the Clamp vent line's pressure relief slit. Pressure 2. Start the engine. Allow it to idle Relief Slit for 10-20 seconds. 3. Remove the vent line clamp.
MAINTENANCE Transmission Oil Maintain the oil level at the bottom of the fill plug hole threads. Use the recommended oil. See page 118 for the part numbers of Polaris products. Transmission Oil Recommendations Lubricant Oil Change Capacity Fill Plug Torque Drain Plug Torque Premium AGL Synthetic Gearcase Lubricant 948 ml 30 N-m 30 N-m Transmission Oil Level 1. Position the vehicle on a level surface. 2. Place the transmission in PARK. 3. Remove the fill plug. 4. Check the oil level.
Transmission Oil MAINTENANCE Transmission Oil Change 1. Position the vehicle on a level surface. 2. Place the transmission in PARK. 3. Remove the fill plug. 4. Remove the drain plug. 5. Drain the oil into a drain pan. 6. Clean the drain plug. 7. Reinstall the drain plug. Torque to specification. See page 72. 8. Add the recommended oil. See page 72. 9. Reinstall the fill plug. Torque to specification. See page 72. 10. Check for leaks. 11. Discard used oil properly.
MAINTENANCE Front Gearcase (Demand Drive) Fluid Fluid Recommendations Gearcase Lubricant Capacity Fill Plug Torque Drain Plug Torque Demand Drive Unit Demand Drive LT Premium Fluid 275 ml 11-14 N-m 15 N-m Use the recommended fluid. Use of other fluids may result in improper operation of components. See page 118 for the part numbers of Polaris products. Maintain the fluid level at the bottom of the fill hole threads. Fill Plug Fill Level Drain Plug Fluid Level 1.
MAINTENANCE Front Gearcase (Demand Drive) Fluid Fluid Change 1. Position the vehicle on a level surface. 2. Place the transmission in PARK. 3. Remove the fill plug. 4. Remove the drain plug. Drain the fluid into a drain pan. 5. Clean the drain plug. 6. Reinstall the drain plug. Torque to specification. See page 74. 7. Add the recommended fluid. 8. Reinstall the fill plug. Torque to specification. 9. Check for leaks. 10. Discard used oil properly.
MAINTENANCE Active Descent Control (ADC) Fluid The ADC fluid reservoir is located under the front box. The reservoir cap is yellow. We recommend the use of Polaris ADC Fluid. See page 118 for the part numbers of Polaris products. Fluid Level 1. Position the vehicle on a level surface. 2. Open the front box cover. 3. Open the access door. 4. View the fluid level in the reservoir. 5. Remove the cap and add the recommended fluid as needed. DO NOT use brake fluid. 6.
MAINTENANCE Active Descent Control (ADC) Fluid Fluid Change 1. Position the vehicle on a level surface. Before performing the fluid change, allow the vehicle to sit for at least 30 minutes. 2. Thoroughly clean the areas around and on the ADC reservoir and bleeder valves (one on each side of the differential). 3. Remove the reservoir cap and diaphragm assembly. Use a shop towel or suction tool to remove debris from the fluid and reservoir.
MAINTENANCE Cooling System Any time the cooling system has been drained for maintenance or repair, replace the coolant with a fresh mixture of antifreeze and water. Drain the cooling system every two years. Add fresh coolant. Polaris recommends the use of Polaris Premium 60/40 anti-freeze/coolant or a 50/50 mixture of high quality aluminum compatible anti-freeze/ coolant and distilled water. Polaris Premium 60/40 is premixed and ready to use. Do not dilute with water.
Cooling System MAINTENANCE Radiator Coolant Escaping steam can cause severe burns. Never remove the pressure cap while the engine is warm or hot. 1. Open the front box cover. 2. Open the access door. 3. Remove the radiator pressure cap. 4. If coolant is not visible, slowly add coolant through the radiator filler neck. 5. Reinstall the pressure cap. Use of a non-standard pressure cap will not allow the recovery system to function properly. Contact your dealer for the correct replacement part. 6.
MAINTENANCE Brake Fluid Check brake fluid levels for both brake systems before each ride. Always maintain brake fluid at the recommended level. Do not overfill. The brakes should feel firm when they're applied. Spongy or weak brakes may indicate a fluid leak or low fluid level. A low fluid level may also mean that brake pads are worn and need to be replaced. Do not operate the vehicle with spongy or weak brakes. See your dealer for service.
Brake Fluid MAINTENANCE Hand Brake The master cylinder is located on the left handlebar. Maintain the fluid level 6 mm below the top edge of the master cylinder. Do not overfill. Master Cylinder Indicator Window 1. Position the vehicle on a level surface. Make sure the handlebars are straight. 2. View the fluid level through the indicator window (eye) on the top of the master cylinder. The eye will appear dark when the fluid level is full. When fluid is low, the eye will be clear. 3.
MAINTENANCE Brake Fluid Foot Brake The foot brake fluid reservoir is located under the seat. 1. Position the vehicle on a level surface. 2. Remove the seat. 3. View the fluid level in the reservoir. 4. Remove the cap and add the recommended fluid as needed. 5. Maintain the fluid level between the minimum and Brake Fluid maximum marks. Do not Reservoir overfill. 6. Reinstall the reservoir cap. 7. Reinstall the seat.
Brakes MAINTENANCE The front and rear brakes are hydraulic disc brakes, activated by applying the foot brake. The handlebar brake is also hydraulic. Both brake systems are self-adjusting. Brake Inspections Perform the following checks to keep the brake systems in good operating condition. Check more often if brakes are used heavily under normal operation. 1. Always keep brake fluid at an adequate level. See page 80. 2. Check the brake systems regularly for fluid leaks. 3.
MAINTENANCE Toe Alignment Do not attempt to adjust alignment. All steering adjustments should be performed by an authorized Polaris dealer. Use the following procedure to check the toe alignment of the vehicle. The recommended toe alignment is 3-6 mm toe out. 1. Position the vehicle on a level surface. 2. Place the handlebars in a Stand straight-ahead position. 3. Tie a length of string String between two stands as shown in the illustration.
Steering Assembly MAINTENANCE Check the steering assembly of the vehicle periodically for loose nuts and bolts. If loose nuts and bolts are found, see your Polaris dealer for service before operating the vehicle. Handlebar Adjustment The handlebars can be adjusted for rider preference. 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.
MAINTENANCE Side Panel Removal 1. Remove the seat. 2. Grasp the rear of the side panel near the rear cab. 3. With a firm motion, pull the panel outward to disengage the side panel from the grommet. 4. Pull the panel downward and rearward to remove it. Footwell Removal Screws 1. Remove the six screws on the bottom of the footwell. 2. Use a flat screwdriver or sidecutters to remove the plastic rivets securing the footwell to the fenders. 3. Remove the footwell.
MAINTENANCE Throttle Cable Freeplay Adjust throttle cable freeplay at the handlebar. 1. Locate the throttle cable adjuster at the handlebar. 2. Squeeze the end of the rubber boot and slide it far enough to expose the end of the inline cable adjuster. Boot 3. Loosen the adjuster lock nut. Lock Nut Adjuster 4. Rotate the boot to turn the adjuster until 1.6-3.2 mm of freeplay is achieved at the thumb lever. Move the throttle lever back and forth while adjusting. 1.6-3.2 mm 5. Tighten the lock nut. 6.
MAINTENANCE Tires Operating your vehicle with worn tires, improperly inflated tires, non-standard tires or improperly installed tires will affect vehicle handling and could cause an accident. Always follow all tire maintenance procedures as outlined in this manual and on the labels on the vehicle. Always use original equipment size and type when replacing tires. Refer to the specifications section beginning on page 116 for recommended tire type, size and pressure.
Tires MAINTENANCE Wheel Removal/Installation 1. Position the vehicle on a level surface. 2. Place the transmission in PARK. 3. Loosen the wheel nuts slightly. 4. Place a suitable stand under the footrest frame to raise the wheel slightly off the ground. 5. Remove the wheel nuts. 6. Remove the wheel. 7. Place the wheel on the hub. 8. Install the wheel nuts finger tight. 9. Lower the vehicle to the ground. 10. Torque the wheel nuts to specification. See torque chart on page 88.
MAINTENANCE Fuel Filter The in-line fuel filter should be replaced by your dealer after every 100 hours of operation or annually. Do not attempt to clean the fuel filter. Air Filter Always clean and replace the air and breather filters at the intervals outlined in the Periodic Maintenance Chart beginning on page 61. 1. Position the vehicle on a level surface. 2. Place the transmission in PARK. 3. Remove the seat. 4. Release the air box cover clips. 5. Remove the air box cover. 6. Loosen the hose clamp.
Breather Filter/Hose MAINTENANCE The breather filter is on the hose between the engine and air box. 1. Remove the left side panel. See page 86. 2. Remove the hose clamps from the filter and pull the filter out of the hoses. 3. Inspect the filter for debris. Blow gently through the filter in the direction of the arrow to check for clogging. Replace a damaged or clogged filter. Breather Filter 4. Check the hoses for cracks, deterioration, abrasion, or leaks. Replace as needed. 5.
MAINTENANCE Lights High Beam Adjustment The headlight beam can be adjusted slightly upward or downward. 1. Position the vehicle on a level surface. The headlight should be approximately 7.6 m from a wall. 2. Place the transmission in PARK. 3. Measure the distance from the floor to the center of the headlight and make a mark on the wall at the same height. Include rider weight on the seat when measuring. 7.6 m X X 4. Start the engine.Turn the headlight switch to high beam. 5.
Lights MAINTENANCE Poor lighting can result in loss of control or an accident. Lights become dirty during normal operation. Wash the headlights and taillights frequently. Hot components can cause serious burns to skin. Do not service the headlamps until they've cooled. Headlight/Position Light Lamp Replacement When servicing a halogen lamp, do not touch the lamp with bare fingers. Oil from your skin leaves a residue, causing a hot spot that will shorten the life of the lamp.
MAINTENANCE Lights Taillight/Brake Light Lamp Replacement 1. Place the transmission in PARK. 2. Rotate the taillight socket counterclockwise to remove it. 3. Remove the lamp. 4. Apply dielectric grease to the socket. 5. Install the new lamp. Test the lamp for proper operation. 6. Reinstall all components in reverse order. Front Turn Signal Lamp Replacement 1. Place the transmission in PARK. 2. Remove the lens attachment screws. 3. Rotate the lamp to remove it. 4. Install the new lamp. 5.
MAINTENANCE Fuse Replacement Fuse Feature Supported 5A Speedometer 15A Electronic Fuel Injection 20A (Main Fuse) Ignition, Lighting 20A Accessories, 12V Power Receptacle If the engine stops or will not start, or if you experience other electrical failures, a fuse may need replacement. Spare fuses are provided in a compartment on the top of the access door. 1. Open the front box cover. 2. Open the access door. 3. Remove the suspect fuse from the fuse panel.
MAINTENANCE Spark Plugs Spark Plug Recommendations Refer to the specifications section beginning on page 116 for the recommended spark plug type and gap for your vehicle. Torque spark plugs to specification. Plug Condition Torque Specification New Spark Plug 12-15 N-m Previously Installed Spark Plug 23-27 N-m Spark Plug Inspection Spark plug condition is indicative of engine operation.
Spark Plugs MAINTENANCE Spark Plug Removal 1. Remove the left side panel. See page 86. 2. Remove the spark plug cap. 3. Use the spark plug wrench to remove the spark plug. Turn the plug counterclockwise to remove it. 4. Inspect the electrodes for wear and carbon buildup. Replace worn or fouled plugs. Verify that the gap is at specification before installation. 5. Reinstall the spark plug. Torque to specification. See page 96. 6. Reinstall the spark plug cap.
MAINTENANCE Vehicle Immersion If your vehicle has been totally submerged in water and it's impossible to have it serviced before further operation, perform the following procedure. NOTICE: If the vehicle stops while fully submerged, major engine damage can result if the machine is not thoroughly inspected. Take the vehicle to your dealer before starting the engine. 1. Move the vehicle out of the water. 2. Remove the spark plug. 3. Drain any water found in the air box.
Vehicle Immersion MAINTENANCE 4. Turn the ignition key past the PARKING LIGHTS position to engage the starter. Engage the starter for only 2-3 seconds. 5. Dry the spark plug. Reinstall the plug or install a new plug. 6. Torque to specification. See page 96. 7. Attempt to start the engine. If necessary, repeat the drying procedure. 8. Have the vehicle serviced by your dealer promptly, whether you succeed in starting it or not. 9.
MAINTENANCE Spark Arrestor Failure to heed the following warnings while servicing the spark arrestor could result in serious injury or death. Never run the engine in an enclosed area. Remove any combustible materials from the area. Wear eye protection and leather work gloves. Do not stand behind or in front of the vehicle while purging. Never go under the vehicle while it's inclined. The exhaust system can get extremely hot. Do not perform service on the spark arrestor while the system is hot.
Spark Arrestor MAINTENANCE 6. If carbon comes out of the exhaust, cover or plug the exhaust outlet. Wear protective gloves. 7. Lightly tap on the exhaust pipe with a rubber mallet while repeating step 5. 8. If particles are still suspected to be in the muffler, elevate the rear of the vehicle 30 cm higher than the front. Block the wheels. 9. Place the transmission in 30 cm PARK. Repeat steps 5 to 7 until no more particles are expelled. 10. Stop the engine. Allow the arrestor to cool. 11.
MAINTENANCE PVT System 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.
PVT System MAINTENANCE PVT Drying There may be some instances when water is accidently ingested into the PVT system. Dry it out before operating. 1. Position the vehicle on a level surface. 2. Place the transmission in PARK. 3. Remove the drain plug. Allow the water to drain completely. Reinstall the drain plug. 4. Start the engine. 5. Apply varying throttle for 10-15 seconds to expel the moisture and air-dry the belt and clutches. Do not hold the throttle wide open for more than 10 seconds. 6.
MAINTENANCE Battery 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.
Battery MAINTENANCE Improperly connecting or disconnecting battery cables can result in an explosion and cause serious injury or death. When removing the battery, always disconnect the negative (black) cable first. When reinstalling the battery, always connect the negative (black) cable last. Battery Removal 1. Place the transmission in PARK. Disconnect the battery hold-down strap. Remove the battery cover (if equipped). 2. On conventional batteries, remove the battery vent tube. 3.
MAINTENANCE Battery Battery Storage Whenever the vehicle is not used for a period of three months or more, remove the battery from the vehicle, ensure that it's fully charged, and store it out of the sun in a cool, dry place. Check battery voltage each month during storage and recharge as needed to maintain a full charge. Polaris recommends maintaining battery charge by using a Polaris Battery Tender charger or by charging about once a month to make up for normal self-discharge.
Battery MAINTENANCE Battery Charging (Conventional Battery) 1. Remove the battery from the vehicle to prevent damage from leaking or spilled electrolyte during charging. See page 105. 2. Charge the battery with a charging output no larger than 1/10 of the battery’s amp/hr rating. Charge as needed to raise the specific gravity to 1.270 or greater. 3. Reinstall the battery. See page 105. Make sure the positive terminal is toward the front of the vehicle.
MAINTENANCE Battery Battery Charging (Sealed Battery) For a refresh charge, follow all instructions carefully. 1. Check the battery voltage with a voltmeter or multimeter. A fully charged battery will register 12.8 V or higher. 2. If the voltage is less than 12.8 volts, recharge the battery at 1.2 amps or less until battery voltage is 12.8 or greater. When using an automatic charger, refer to the charger manufacturer's instructions for recharging.
Cleaning and Storage MAINTENANCE Washing the Vehicle Keeping your Polaris vehicle clean will not only improve its appearance but it can also extend the life of various components. High water pressure may damage components. Polaris recommends washing the vehicle by hand or with a garden hose, using mild soap. Certain products, including insect repellents and chemicals, will damage plastic surfaces. Do not allow these types of products to contact the vehicle. 1.
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.
Cleaning and Storage MAINTENANCE 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. 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 109. Stabilize the Fuel 1. Fill the fuel tank. 2. Add Polaris Carbon Clean Fuel Treatment or Polaris Fuel Stabilizer. Follow the instructions on the container for the recommended amount.
Cleaning and Storage MAINTENANCE Storage Tips Fluid Levels Inspect the fluid levels. Add or change fluids as recommended in the Periodic Maintenance Chart beginning on page 61. • Demand drive unit (front gearcase) • ADC fluid (change every two years) • Rear gearcase (if equipped) • Transmission • Brake fluid (change every two years and any time the fluid looks dark or contaminated) • Coolant (test strength/fill) Fog the Engine 1. Treat the fuel system with Polaris Carbon Clean. See page 112. 2.
MAINTENANCE Cleaning and Storage Storage Tips Inspect and Lubricate Inspect all cables and lubricate all areas of the vehicle as recommended in the Periodic Maintenance Chart beginning on page 61. Battery Storage See pages 106-107 for storage and charging procedures. Storage Area/Covers 1. Set the tire pressure and safely support the vehicle with the tires slightly off the ground. 2. Be sure the storage area is well ventilated. 3. Cover the vehicle with a genuine Polaris cover.
Transporting the Vehicle MAINTENANCE Follow these procedures when transporting the vehicle. 1. Stop the engine. 2. Place the transmission in PARK. 3. Secure the fuel cap, oil cap and seat. 4. Remove the key to prevent loss during transporting. 5. Always tie the frame of the Tractor to the transporting unit securely with suitable straps or rope. Do not attach tie straps to the front Aarm bolt pockets, racks or handlebars.
SPECIFICATIONS Sportsman 500 EFI Tractor Maximum Weight Capacity 420 lbs. (191 kg) (includes operator, cargo, accessories, tongue weight) Dry Weight 775 lbs. (352 kg) Front Rack/Storage Box Capacity 90 lbs. (41 kg) Rear Rack Capacity 180 lbs. (82 kg) Rear Hitch Tongue Capacity 120 lbs. (54.4 kg) (Rear rack capacity and tongue weight not to exceed 180 lbs./82 kg) Rear Hitch Towing Capacity 1225 lbs. (555 kg) on level ground Front Hitch Tongue Capacity 85 lbs.
SPECIFICATIONS Sportsman 500 EFI Tractor Transmission Gear Reduction, Low Gear Reduction, Reverse Gear Reduction, High Drive Ratio, Front Tires/Pressure, Front Tires/Pressure, Rear Brake, Hand Brake, Foot Brake, Parking Headlight Parking Lights Taillights Brake Light Instrument Cluster Automatic EBS (Engine Braking System) w/E-Z Shift H/L/N/R/P 23.91:1 21.74:1 10.57:1 3.82:1 25x8-12 / 5 psi (34.5 kPa) 25x12.5-12 / 5 psi (34.
POLARIS PRODUCTS Part Number 2870791 2876244 2876245 2873602 2873603 2876144 2876251 2870465 2871323 2871534 2871312 2871322 2871423 2871460 2871515 2871551 2871329 2871326 2870652 2872189 2871956 2859044 118 Description Engine Lubricant Fogging Oil (12 oz. Aerosol) PS-4 PLUS Performance Synthetic 2W-50 4-Cycle Oil (.95 l) PS-4 PLUS Performance Synthetic 2W-50 4-Cycle Oil (3.8 l) Gearcase / Transmission Lubricants Premium AGL Synthetic Gearcase Lubricant (.95 l) Premium AGL Synthetic Gearcase Lube (3.
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 (5-11 kmh) Insufficient warm-up at low ambient temperatures TROUBLESHOOTING Solution Use low range. Use low range or turn around using the K-turn (see page 50). Drive at a higher speed or use low range more frequently. Warm the engine at least 5 minutes.
TROUBLESHOOTING Engine Does Not Rotate Possible Cause Low battery voltage Loose battery connections Loose solenoid 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 See your dealer Set gap to specs or replace plugs Engine Runs Irregularly, Stalls or Misfires Possible Cause Fouled or defective spark plug(s) Worn or defective spark plug wires Incorrect spark plug gap or heat range Loose ignition connections Water present in fuel Low battery voltage Kinked or plugged fuel tank vent l
TROUBLESHOOTING Engine Stops or Loses Power Possible Cause Out of fuel Kinked or plugged fuel vent line Water is present in fuel Old or non-recommended fuel Fouled or defective spark plug(s) Worn or defective spark plug wires Incorrect spark plug gap or heat range Loose ignition connections Low battery voltage Clogged air filter Reverse speed limiter malfunction Electronic throttle control malfunction Other mechanical failure Overheated engine Solution Refuel, cycle key to ON position three times for 5 sec
LIMITED WARRANTY WARRANTY Polaris Industries Inc., 2100 Highway 55, Medina, MN 55340, gives a TWO YEAR LIMITED WARRANTY on all components of the Polaris Tractor against defects in material or workmanship. This warranty covers the parts and labor charges for repair or replacement of defective parts which are covered by this warranty. This warranty begins on the date of purchase. This warranty is transferable to another consumer during the warranty period through a Polaris dealer.
WARRANTY WARRANTY COVERAGE AND EXCLUSIONS: LIMITATIONS OF WARRANTIES AND REMEDIES The Polaris limited warranty excludes any failures that are not caused by a defect in material or workmanship. This warranty does not cover accidental damage, normal wear and tear, abuse or improper handling.
HOW TO OBTAIN WARRANTY SERVICE WARRANTY If your vehicle requires warranty service, you must take it to a Polaris dealer authorized to repair Polaris Tractors. When requesting warranty service you must present your copy of the Warranty Registration form to the dealer. (THE COST OF TRANSPORTATION TO AND FROM THE DEALER IS YOUR RESPONSIBILITY). Polaris suggests that you use your original selling dealer; however, you may use any Polaris Servicing Dealer to perform warranty service.
MAINTENANCE LOG Present this section of your manual to your dealer each time your vehicle is serviced. This will provide you and future owners with an accurate log of maintenance and services performed.
MAINTENANCE LOG DATE KILOMETERS OR HOURS TECHNICIAN SERVICE PERFORMED / COMMENTS 127
INDEX 0-9 C 4X4 System . . . . . . . . . . . . . . . . . 28-29 Cold Weather Operation . . . . . . . . . . 43 Coolant Bottle . . . . . . . . . . . . . . . . . . 78 Coolant, Radiator. . . . . . . . . . . . . . . . 79 Cooling System . . . . . . . . . . . . . . 78-79 Corrosion Removal, Chrome. . . . . . 111 A Accessories . . . . . . . . . . . . . . . . . . 114 Active Descent Control Fluid . . . 76-77 Active Descent Control System. . . . 30 ADC System . . . . . . . . . . . . . . . . . . 30 Air Filter . . . .
INDEX F H Fluid Change ADC Fluid. . . . . . . . . . . . . . . . . 77 Demand Drive. . . . . . . . . . . . . . 75 Engine Oil . . . . . . . . . . . . . . 68-71 Front Gearcase . . . . . . . . . . . . . 75 Transmission . . . . . . . . . . . . . . . 73 Fluid Level ADC Fluid. . . . . . . . . . . . . . . . . 76 Brake Fluid . . . . . . . . . . . . . . 81-82 Demand Drive. . . . . . . . . . . . . . 74 Engine Oil . . . . . . . . . . . . . . . . . 67 Front Gearcase . . . . . . . . . . . . . 74 Transmission . . . . . .
INDEX O S Oil Change Engine . . . . . . . . . . . . . . . . . 68-71 Transmission . . . . . . . . . . . . . . 73 Oil Level Engine . . . . . . . . . . . . . . . . . . . 67 Transmission . . . . . . . . . . . . . . 72 Oil Pump Priming . . . . . . . . . . . . . . 71 Oil Recommendations Engine Oil . . . . . . . . . . . . . . . . 66 Transmission . . . . . . . . . . . . . . 72 Override Switch . . . . . . . . . . . . . . . . 20 Safety Training . . . . . . . . . . . . . . . . . . 7 Seat . . . . . . . . . . . . . .
INDEX T V Tires . . . . . . . . . . . . . . . . . . . . . . 88-89 Wheel Installation . . . . . . . . . . . 89 Wheel Nut Torque . . . . . . . . . . 88 Wheel Removal. . . . . . . . . . . . . 89 Toe Alignment . . . . . . . . . . . . . . . . . 84 Towing a Disabled Vehicle. . . . . . . 115 Towing Capacities . . . . . . . . . . . . . . 58 Towing Loads . . . . . . . . . . . . . . . 58-59 Training, Safety . . . . . . . . . . . . . . . . . 7 Transmission . . . . . . . . . . . . . . . . . . . 27 Transmission Oil. .
