Polaris 2015 Polaris M1400- Manuals

4 INTRODUCTION The POLARIS M1400 is a utility vehicle. Never operate on public roads. This vehicle does not meet National Highway Traffic Safety Administration (NHTSA) regulations for opera-tion on public streets, roads and highways. Familiarize yourself with all laws and regulations concerning the ...

6 INTRODUCTION Vehicle Identification Numbers Record your vehicle's identification numbers and key number in the spaces provided below. The Vehicle Identification Number (VIN) indicates the model year, model type and serial number of your vehicle. The VIN is stamped on the left rear frame. The VIN i...

7 INTRODUCTION European Vibration and Noise The driver-perceived noise and hand/arm and whole body vibration levels of this machinery is measured per prEN 15997. The operating conditions of the machinery during testing: The vehicles were in like-new condition. The environment was controlled as indic...

8 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 instructio...

9 SAFETY Safety Labels and Locations Discretionary Warning WARNING Improper vehicle use can result in Severe Injury or Death. NEVER Operate: • At speeds too fast for your skills or the conditions. • After or while using Alcohol or Drugs. • On extreme off-road terrain or extreme slopes. • On public r...

10 SAFETY Safety Labels and Locations Passenger/Tire Pressure Warning WARNING • Passengers can be thrown off. This can cause serious injury or death. • Never carry passengers in cargo box. WARNING IMPROPER TIRE PRESSURE OR OVERLOADING CAN CAUSE LOSS OF CONTROL RESULTING IN SERIOUS INJURY OR DEATH. •...

11 SAFETY Operator Safety Serious injury or death can result if you do not follow these instructions and procedures, which are outlined in further detail within your owner's manual. • Read this entire manual and all labels carefully. Follow the operating procedures described. • Never allow anyone un...

13 SAFETY Operator Safety • Always stop the engine before refueling. Remove flammable material containers from the box before filling them with fuel. Make sure the refueling area is well ventilated and free of any source of flame or sparks. Gasoline is extremely flammable. See page 15 for fuel safet...

15 SAFETY Operator Safety Handling Gasoline Gasoline is highly flammable and explosive under certain conditions. • Always exercise extreme caution whenever handling gasoline.• Always turn off the engine when refueling.• Always refuel outdoors or in a well ventilated area free of any source of flame ...

18 FEATURES AND CONTROLS Component Locations Console Hip Bar Cargo Box Headlights Front Bumper/Brush Guard Receiver Hitch Tailgate Taillight

19 FEATURES AND CONTROLS Console Instrument Cluster MODE Button Gear Selector Cup Holder Ignition\Light Switch Brake Pedal Throttle Pedal Storage Compartment Auxiliary Outlet Storage Tray Dump Box Switch

20 FEATURES AND CONTROLS Console Auxiliary 12-Volt Terminal Board The 12-volt terminal board is located under the hood. It contains constant 12-volt, switched 12-volt and ground terminals that can be used to power auxiliary lights and accessories. The terminals are limited to 10 amps. Auxiliary Outl...

21 FEATURES AND CONTROLS Console Gear Selector Using Low Range Always shift into low gear for any of the following conditions.• Operating in rough terrain or over obstacles• Loading the vehicle onto a trailer• Towing heavy loads Brake Pedal Push the brake pedal toward the floor to slow or stop the v...

22 FEATURES AND CONTROLS Fuel Cap The fuel tank filler cap is located on the right-hand side of the vehicle near the passenger 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 1...

23 FEATURES AND CONTROLS Seat Belts This POLARIS vehicle is equipped with three-point lap and diagonal seat belts for the operator and passenger. Always make sure the seat belts are secured for all riders before operating. The driver's seat belt is equipped with a seat belt interlock. Vehicle speed ...

24 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 The speedometer displays vehicle spee...

25 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 cl...

26 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 display either standard or metric units of measurement. Tip: To exit the set-up mode at any time, wai...

27 FEATURES AND CONTROLS Instrument Cluster Rider Information Center Odometer Mode The odometer records and displays the distance traveled by the vehicle. Trip Meter Mode The trip meter records the distance traveled by the vehicle if reset before each trip. To reset, select the trip meter mode. Pres...

28 FEATURES AND CONTROLS Instrument Cluster Rider Information Center Engine Error Codes The error screen displays 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 wil...

29 OPERATION 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. Break-In Period The break-in period for y...

30 OPERATION 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. Pre-Ride Inspection Failure to inspect an...

31 OPERATION Driving Procedure 1. All riders should wear substantial foot- wear, long pants and a close-fitting shirt. A hard hat or helmet and approved eye protection are recommended when appro-priate for working or riding conditions. 2. Sit in the driver's seat. 3. Start the engine and allow it to...

32 OPERATION Driving with a Passenger 1. Perform the pre-ride inspection. See page 30. 2. Make sure all passengers are at least 12 years of age and tall enough to comfortably and safely sit in a passenger seat with the seat belt secured, put both feet on the floor and grasp the hand hold. 3. All rid...

33 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 us...

34 OPERATION Driving Uphill Whenever traveling uphill, follow these precautions: 1. Always travel straight uphill. 2. Avoid excessively steep hills. 3. Keep both feet on the floor. 4. Always check the terrain carefully before ascending any hill. Never climb hills with excessively slippery or loose s...

35 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 sidehill is unavoidable , follow these precautions: 1. Slow down. 2. E...

36 OPERATION Driving Through Water Your POLARIS M1400 can operate through water up to a maximum recommended depth equal to the floorboards. NOTICE: Immersion can result in major damage if the vehicle isn't serviced correctly and promptly. After immersion, always take the vehicle to your dealer servi...

37 OPERATION Hauling Cargo Hauling cargo improperly can alter vehicle handling and may cause loss of control or brake instability, which can result in serious injury or death. Always follow these precautions when hauling cargo: Never exceed the maximum weight capacity of the vehicle. When determinin...

38 OPERATION Towing Loads 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. Do not operate the vehicle faster than 10 MPH (16...

39 OPERATION Dumping the Cargo Box 1. Select a level site to dump the cargo box. Do not attempt to dump or unload the vehicle while parked on an incline. 2. Apply the brakes. 3. Place the transmission in PARK. 4. Dismount the vehicle. 5. Ensure that the cargo is positioned evenly or toward the front...

40 OPERATION Transporting the Vehicle When transporting the POLARIS M1400 for a long distance or on public streets, always use a trailer with an approved load rating greater than the POLARIS M1400 curb vehicle weight of 1060 lbs. (481 kg) plus any installed accessories or cargo. Follow these guideli...

41 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. Improper winch use can result in SEVERE INJURY or DEATH. Always follow all winch instructions and warnings in this manual. Your winch may...

43 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. Improper winch use can result in SEVERE INJURY or DEATH. Always follow all wi...

44 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 to secure the load to the winch cable. Tip: A “tow strap” is NOT in...

45 WINCH GUIDE Winch Operation 8. Read and adhere to the following information for winch damping to ensure safe winch use. A. In order to absorb energy that could be released by a winch cable failure, always place a “damper” on the winch cable. A damper can be a heavy jacket, tarp, or other soft, de...

47 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 GEM dealer. WARNING! Use of worn or damaged cable could lead to sudden failure and SEVERE INJURY. 1. Always inspect your winch...

48 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 D...

49 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....

50 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 require-ments. Operation on Public Lands in the U.S.A. Your POLARIS vehicl...

51 MAINTENANCE Periodic Maintenance Chart Careful periodic maintenance will help keep your vehicle in the safest, most reliable condition. Inspection, adjustment and lubrication of important components are explained in the periodic maintenance chart. Inspect, clean, lubricate, adjust and replace par...

54 MAINTENANCE Lubrication Recommendations Check and lubricate all components at the intervals outlined in the Periodic Maintenance Chart beginning on page 51, or more often under severe use, such as wet or dusty conditions. Items not listed in the chart should be lubricated at the general lubricati...

55 MAINTENANCE Engine Oil Always check and change the oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 51. Always use the recommended engine oil. See page 54. NOTICE: Allowing dirt or debris to enter the engine can result in serious engine damage. Always clean away a...

56 MAINTENANCE Engine Oil Oil and Filter Change Always check and change the oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 51. Always change the oil filter whenever changing oil. The engine drain plug is located on the bottom of the crankcase. 1. Position the vehic...

57 MAINTENANCE Engine Oil Oil and Filter Change 12. Lubricate the o-ring for the new filter with a film of fresh engine oil. Check to make sure the o-ring is in good condition. Install the o-ring to the filter cover. 13. Reinstall the oil filter spring, then install the new filter. 14. Reinstall the...

58 MAINTENANCE Gearcases Gearcase Specification Chart Transmission (Main Gearcase) Always check and change the transmission oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 51. Maintain the oil level even with the bottom thread of the fill plug hole. Refer to the Gea...

59 MAINTENANCE Gearcases Front Gearcase (if equipped) Always check and change the front gearcase oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 51. Maintain the oil level even with the bottom thread of the fill plug hole. Refer to the Gearcase Specifications Chart ...

60 MAINTENANCE Spark Plugs Spark Plug Recommendations Refer to the specifications section beginning on page 82 for the recommended spark plug type for your vehicle. Always torque spark plugs to specification. NOTICE: Using non-recommended spark plugs can result in serious engine damage. Always use P...

61 MAINTENANCE Cooling System 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) exces...

62 MAINTENANCE Cooling System Overflow Bottle Coolant Level Always check and change the coolant at the intervals outlined in the Periodic Maintenance Chart beginning on page 51. Maintain the coolant level between the minimum and maximum marks on the bottle (when the fluid is cool). 1. Position the v...

63 MAINTENANCE POLARIS Variable Transmission (PVT) System 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...

65 MAINTENANCE POLARIS Variable Transmission (PVT) System PVT Drying There may be some instances when water is ingested into the PVT system. Use the following instructions to dry it out before operating. 1. Position the vehicle on a level surface. 2. Remove the red drain plug on the outer clutch cov...

66 MAINTENANCE Filter Systems Air Filter Always change the air filter at the intervals outlined in the Periodic Maintenance Chart beginning on page 51. 1. Lift the cargo box. 2. Clean all dirt and debris from the air box area. 3. Unlatch the two (2) cover clips and carefully remove the air box cover...

67 MAINTENANCE Spark Arrester Failure to heed the following warnings while servicing the spark arrester could result in serious injury or death. • Do not perform service on the spark arrester while the system is hot. Exhaust system temperatures can reach 1000° F. Allow components to cool sufficientl...

68 MAINTENANCE Brakes The front and rear brakes are hydraulic disc type brakes. Press down on the brake pedal to engage the brakes. See page 21. Brake Fluid Inspect the brake system routinely. Inspect the level of the brake fluid before each operation. WARNING! After opening a bottle of brake fluid,...

69 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 51. 1. Position the vehicle on a level surface. 2. Lightly turn the steering wheel left and right. There should ...

70 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 resulting in serious injury or death. Always follow all tire maintenance procedures as outlined in this ma...

71 MAINTENANCE Tires Wheel Installation 1. Place the transmission in PARK. Place the wheel in the correct position on the wheel hub. Be sure the valve stem is toward the outside and rotation arrows on the tire point toward forward rotation. WARNING! Improperly installed wheels can adversely affect t...

72 MAINTENANCE Lights Poor lighting can result in reduced visibility when driving. Headlight and taillight lenses become dirty during normal operation. Clean lights frequently and replace burned out lamps promptly. Do not operate this vehicle at night or in low light conditions until the headlight i...

73 MAINTENANCE Lights Headlight Beam Adjustment 1. Place the vehicle on a level surface with the headlight approximately 25 ft. (7.6 m) from a wall. 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 key...

74 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...

75 MAINTENANCE Battery Battery Removal 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)...

76 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 77 before installing the battery. An optional extreme use batt...

77 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 75. 2. Charge the battery with a charging output no larger than 1/10 of the battery’s amp/hr rating. Charge as needed ...

78 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. NOTICE: High water pressure may damage components. POLARIS recommends washing the vehicle by hand or with a garden ho...

79 MAINTENANCE Cleaning and Storage Polishing the Vehicle POLARIS recommends the use of common household aerosol furniture polish for polishing the finish on your POLARIS vehicle. Follow the instructions on the container. Polishing Tips • Avoid the use of automotive products, some of which can scrat...

80 MAINTENANCE Cleaning and Storage Storage Tips Fluid Levels Inspect the fluid levels. Add or change fluids as recommended in the Periodic Maintenance Chart beginning on page 51.• Front and rear gearcase fluid (if equipped)• Transmission fluid• Brake fluid (change every two years and any time the f...

81 MAINTENANCE Storing the Vehicle Any time the vehicle will be parked for more than a few hours, follow the recommended storage procedures: 1. Make any necessary repairs and clean the vehicle. See page 78. 2. Inspect all cables and lubricate all areas of the vehicle as recommended in the Periodic M...

82 SPECIFICATIONS POLARIS M1400 Dimensions Maximum Weight Capacity(includes weight of operator, pas-senger, cargo, accessories) 1450 lbs. (658 kg) Dry Weight 1060 lbs. (481 kg) Ground Clearance 8.5 in. (21.6 cm) Length 114.5 in. (291 cm) Width 56.5 in. (143.5 cm) Height 73 in. (185.4 cm) Cargo Box (...

83 SPECIFICATIONS POLARIS M1400 Brake System Brakes 4-Wheel hydraulic disc w/dual bore front calipers Engine and Suspension Engine Dual overhead cam, 4 valve 4 stroke single cylinder Displacement 325 cc Bore x Stroke (mm) 78mm x 68mm Alternator Output 460 W @ 3000 RPM Compression Ratio 11.5:1 Starti...

84 POLARIS PRODUCTS Part Number Description Engine Lubricant 2870791 Fogging Oil (12 oz./355 ml Aerosol) 2876244 PS-4 Full Synthetic 5W-50 4-Cycle Oil (qt./.95 l) 2876245 PS-4 Full Synthetic 5W-50 4-Cycle Oil (gal./3.8 l) 2878920 PS-4 Extreme Duty Synthetic 10W-50 4-Cycle Oil (qt./.95 l) 2878919 PS-...

85 TROUBLESHOOTING Drive Belt Wear/Burn Possible Cause Solution Driving onto a pickup or tall trailer in high range Use low range during loading. Starting out going up a steep incline Use low range. See warnings on page 34. Driving at low RPM or ground speed (3-7 MPH) Drive at a higher speed or use ...

86 TROUBLESHOOTING Engine Doesn't Turn Over Engine Turns Over, Fails to Start Engine Backfires Engine Pings or Knocks Possible Cause Solution Low battery voltage Recharge the battery to 12.8 VDC Loose battery connections Check all connections and tighten Loose solenoid connections Check all connecti...

87 TROUBLESHOOTING Engine Runs Irregularly, Stalls or Misfires Engine Stops or Loses Power Possible Cause Solution Fouled or defective spark plug Inspect, clean and/or replace spark plug Worn or defective spark plug wires See your GEM dealer Incorrect spark plug gap or heat range Set gap to specs or...

88 WARRANTY Limited Warranty POLARIS Industries Inc., 2100 Highway 55, Medina, MN 55340 (POLARIS) gives a TWO YEAR 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 eff...

89 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, ...

90 WARRANTY How To Obtain Warranty Service If your vehicle requires warranty service, you must take it to a GEM 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 RE...

91 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 governm...

92 WARRANTY U.S.A. EPA Emissions Limited Warranty The following parts are considered emission-related components for evaporative emissions: *As related to the evaporative emission control system.The exclusive remedy for breach of this limited warranty shall be, at the exclusive option of POLARIS, re...

93 MAINTENANCE LOG Use the following chart to record periodic maintenance. DATE MILES (KM) OR HOURS TECHNICIAN SERVICE PERFORMED / COMMENTS

95 INDEX A Adjustment, Headlight Beam . . . . . . . . . . . . . . . . 73Air Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66Air Filter Cleaning . . . . . . . . . . . . . . . . . . . . . . . . 66Auxiliary 12-Volt Terminal Board . . . . . . . . . . . . 20Auxiliary Outlets. . ....