Polaris 9920632 - Manual

5 KNOW YOUR VEHICLE As the operator of the vehicle, you are responsible for your personal safety, the safety of others (including your passenger), and the protec-tion of our environment. Read and understand your owner's manual, which includes valuable information about all aspects of your vehicle, i...

6 SAFETY Safety Decals and Locations Warning decals have been placed on the ATV for your protection. Read and follow the instructions of the decals on the ATV carefully. If any of the decals depicted in this manual differ from the decals on your ATV, always read and follow the instructions of the de...

7 SAFETY Safety Decals and Locations General Warning WARNINGImproper ATV use can result in SEVERE INJURY or DEATHALWAYS USE AN APPROVED HELMET AND PROTECTIVE GEAR FOR OPERATOR AND PASSENGERNEVER USE ON PUBLIC ROADSNEVER CARRY MORE THAN ONE PASSENGERNEVER USE WITH DRUGS OR ALCOHOLNEVER operate:• with...

8 SAFETY Safety Decals and Locations Passenger Safety Warning WARNINGPASSENGER SAFETY to reduce the risk of SEVERE INJURY or DEATHNEVER CARRY A PASSENGER UNDER AGE 12NEVER CARRY MORE THAN ONE PASSENGERNEVER RIDE AFTER USING DRUGS OR ALCOHOLNEVER carry a passenger too small to firmly plant feet on fo...

9 SAFETY Safety Decals and Locations Tire Pressure/Load Warning WARNINGIMPROPER TIRE PRESSURE OR OVERLOADING can cause loss of control resulting in SEVERE INJURY OR DEATH.TIRE PRESSURE IN PSI (KPa): FRONT 5 (34.5) REAR 5 (34.5)MAXIMUM WEIGHT CAPACITY (Gross Vehicle Weight) INCLUDING MACHINE, OPERATO...

10 SAFETY Safety Decals and Locations Rack Warning, Front WARNINGDO NOT TOW FROM RACK OR BUMPER. Vehicle damage or tipover may result causing severe injury or death. Tow only from tow hooks or hitch. Maximum combined Front Rack and Container Load: 90 lbs. (41 kg) Clutch Cover Warning WARNINGNO STEP•...

11 SAFETY Safety Decals and Locations Reverse Override Warning WARNINGPushing reverse override button may cause sudden increases in power and traction if too much throttle is applied. Loss of control or forward flipover may result, especially in AWD. See Owner's Manual. Box Warning WARNINGRemove fla...

12 SAFETY Safe Riding Gear Always wear appropriate clothing when riding an ATV. Wear protective clothing for comfort and to reduce the chance of injury. Helmet Wearing a helmet can prevent a severe head injury. Whenever riding a Polaris vehicle, always wear a helmet that meets or exceeds established...

13 SAFETY Safe Riding Gear Eye Protection Do not depend on eyeglasses or sunglasses for eye protection. When-ever riding a Polaris vehicle, always wear shatterproof goggles or use a shatterproof helmet face shield. Polaris recommends wearing approved Personal Protective Equipment (PPE) bearing marki...

14 SAFETY Rider Safety Age Restrictions This vehicle is an ADULT VEHICLE ONLY. Operation is prohibited for anyone under 16 years of age. Never allow anyone under 12 years of age to ride as a passenger on this 2-up ATV. WARNING Failure to follow the warnings contained in this manual can result in sev...

15 SAFETY Rider Safety Safety Training ATV safety training is a top priority for Polaris. When you purchased your new ATV, your dealer instructed you on the authorized ATV RiderCourse sm available to you and your eligible family members. This training is included in the purchase price of your ATV. P...

16 SAFETY Rider Safety The following signal words and symbols appear throughout this manual and on your vehicle. Your safety is involved when these words and sym-bols are used. Become familiar with their meanings before reading the manual. The safety alert symbol , on your vehicle or in this manual,...

19 SAFETY Rider Safety • Always follow proper procedures for going downhill and for braking on hills. Check the terrain carefully before you start down a hill. Shift your weight uphill. Never go down a hill at high speed. Avoid going down a hill at an angle, which would cause the vehicle to lean sha...

20 SAFETY Rider Safety • Always check for obstacles or people behind the ATV before operat- ing in reverse. Be aware that a passenger can obstruct your view. When it's safe to proceed in reverse, move slowly and avoid turning at sharp angles. • Always use the size and type of tires specified for you...

21 SAFETY Rider Safety Equipment Modifications We are concerned for the safety of our customers and for the general public. Therefore, we strongly recommend that consumers do not install on a Polaris ATV any equipment that may increase the speed or power of the vehicle, or make any other modificatio...

38 FEATURES AND CONTROLS Switches Mode/Reverse Override Switch This vehicle is equipped with a reverse speed limiter system.To gain additional power while backing, depress the override switch. NOTE: The override switch also allows activation of All Wheel Drive in reverse, if the AWD switch is on. Th...

39 FEATURES AND CONTROLS Switches Engine Stop Switch Move the stop switch either left or right to the OFF position to stop the engine quickly. The engine will not start or run when the switch is off. NOTE: Both the main switch and the engine stop switch will shut off all electri- cal power to the ve...

40 FEATURES AND CONTROLS Throttle Lever Engine speed and vehicle move-ment are controlled by pressing the throttle lever. The throttle lever is spring loaded. Engine speed returns to idle when the lever is released. This ATV is equipped with Polaris Electronic Throttle Control (ETC), which is design...

41 FEATURES AND CONTROLS Brake Lever Squeeze the brake lever toward the handlebar to apply the front and rear brakes. These brakes are hydraulically activated disc type brakes that are activated by only one lever. Always test brake lever travel and master cylinder fluid level before riding. When squ...

42 FEATURES AND CONTROLS Master Cylinder/Brake Fluid Check the brake fluid in the master cylinder before each ride. The fluid level can be seen through an indicator window on the top of the master cylinder. This eye will appear dark when the fluid level is full. When fluid is low, the eye will be cl...

43 FEATURES AND CONTROLS Parking Brake Locking the Parking Brake 1. Place the transmission in PARK. 2. Squeeze and release the brake lever two or three times, then squeeze and hold. 3. Push the parking brake lock forward to engage the lock. 4. Release the brake lever. 5. To release the parking brake...

44 FEATURES AND CONTROLS Auxiliary Foot Brake The auxiliary brake system is intended to be used as a backup for the main brake system. Should the main system fail, use the auxiliary foot brake. NOTE: Since this is a rear brake only, it will not be as effective as the all-wheel single lever system. T...

45 FEATURES AND CONTROLS Automatic Transmission Gear Selector The transmission gear selector is located on the right side of the vehicle. H: High GearL: Low GearN: NeutralR: ReverseP: Park Whenever the ATV is left unattended, always place the transmission in PARK and lock the parking brake. Belt Lif...

46 FEATURES AND CONTROLS Recoil Starter (500 EFI) If the battery is too weak to start the engine, use the recoil starter. Follow the starting procedures on page 63, cranking the engine with the recoil starter instead of the main key switch. 1. Grasp the recoil starter rope handle tightly. 2. Pull sl...

47 FEATURES AND CONTROLS All Wheel Drive (AWD) System The All Wheel Drive system is controlled by the AWD switch. When the switch is on 2X4 (cen-ter position), the ATV is in two-wheel drive at all times. When the switch is on AWD (left position), the ATV is in all wheel drive and the AWD indicator l...

48 FEATURES AND CONTROLS All Wheel Drive (AWD) System Engaging AWD The AWD switch may be turned on or off while the vehicle is moving. Initially, the vehicle's electronic system will not enable the AWD until the engine RPM is below 3100. Once enabled, the AWD remains enabled until the AWD switch is ...

49 FEATURES AND CONTROLS Active Descent Control (ADC) System The ADC system (if equipped) allows engine braking to all four wheels when the vehicle descends a hill or incline. If your ATV is equipped with Active Descent Control, always engage AWD before ascending or descending a hill. Engaging Activ...

50 FEATURES AND CONTROLS Passenger Seat Always make sure the passenger seat lock-out is functioning properly before operating with a passenger. Do not operate the vehicle with the seat in the 2-up position when oper-ating without a passenger. Always return the seat to the 1-up position for single-ri...

51 FEATURES AND CONTROLS Passenger Seat Seat Conversion 5. Lift the adjustment latch at the top of the passenger backrest. Raise the backrest to the desired position. Release the latch, making sure it locks into one of the three operating positions. NOTE: The backrest must be moved out of the lowest...

52 FEATURES AND CONTROLS Instrument Cluster Your ATV is equipped with an instrument cluster that senses vehicle speed from a sensor in the transmission. The instrument cluster mea-sures distance in miles as well as hours of operation. It also includes a reverse speed limiter function that limits the...

53 FEATURES AND CONTROLS Instrument Cluster Rider Information Center The rider information center is located in the instrument cluster. All seg-ments will light up for 2.5 seconds at start-up. NOTE: If the instrument cluster fails to illuminate, a battery over-voltage may have occurred and the instr...

54 FEATURES AND CONTROLS Instrument Cluster Rider Information Center Standard Modes Use the MODE button to toggle through the mode options. The reverse override button is also the MODE button. See page 38. NOTE: The transmission cannot be in reverse when using this feature. Odometer Mode The odomete...

55 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 move-ment of the tires will also cause the gauge to exit the diagnostic mode. T...

56 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. AWD Diagnostic Screen The gauge indicates whether or not current is flowing throug...

57 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...

58 FEATURES AND CONTROLS Instrument Cluster Rider Information Center Downloading Codes The EFI diagnostic mode is for informational purposes only. Please see your Polaris dealer for all major repairs. See page 59 for Blink Codes and Failure Descriptions. Use the follow-ing procedure to download blin...

59 FEATURES AND CONTROLS Instrument Cluster Rider Information Center Downloading Codes Blink Code Failure Description 12 BEGIN SEQUENCE 45 Barometric Pressure/Manifold Air Pressure Sensor Low 46 Barometric Pressure/Manifold Air Pressure Sensor High 41 Air Temp Sensor Low Voltage 41 Air Temp Sensor H...

60 OPERATION Fuel Safety WARNING Gasoline is highly flammable and explosive under certain conditions.• Always exercise extreme caution whenever handling gasoline.• Always refuel with the engine stopped, and outdoors or in a well ventilated area. • Do not smoke or allow open flames or sparks in or ne...

61 OPERATION Break-In Period The break-in period for your new Polaris ATV is the first ten hours of operation, or the time it takes to use the first two full tanks of gasoline. No single action on your part is as important as following the proce-dures for a proper break-in. Careful treatment of a ne...

62 OPERATION Pre-Ride Checklist WARNING If a proper inspection is not done before each use, severe injury or death could result. Always inspect the vehicle before each use to ensure it's in proper operating condition. Item Remarks Page Passenger seat lock-out Ensure proper operation 50 Brake system/...

63 OPERATION Starting the Engine 1. Position the vehicle on a level surface. 2. Place the transmission in PARK. 3. Lock the parking brake. NOTE: The starter interlock will prevent the engine from starting if the trans- mission is in gear and the brake is not engaged. 4. Sit on the vehicle and move t...

64 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.Never carry cargo...

65 OPERATION Hauling Cargo Your ATV has been designed to carry or tow a certain amount of load. Always read and understand the load distribution warn-ing labels on the vehicle, and never exceed the weight capacities outlined in the specifications section of the owner's manual and on the safety decal...

66 OPERATION Hauling Cargo Towing Loads Always attach a towed load to the hitch point. If towing a load, reduce rear rack cargo weight by the amount of tongue weight. The combina-tion of rear rack cargo weight and tongue weight must not exceed the rear rack capacity. Maximum Towing Capacities Do not...

67 OPERATION Hauling Cargo Dumping Cargo 1. Select a level site to dump the cargo box. Do not attempt to dump or unload the vehicle while parked on an incline. 2. Place the transmission in PARK. 3. Lock the parking brake. 4. Dismount the vehicle. 5. Lower the tailgate. 6. Pull the cargo box release ...

68 OPERATION Driving Procedures 1. Wear protective riding gear. See page 12. 2. Perform the pre-ride inspection. See page 62. 3. Place the transmission in PARK. 4. Lock the parking brake. 5. Mount the vehicle from the left side. 6. Sit upright with both feet on the footrests and both hands on the ha...

69 OPERATION Turning the Vehicle Both rear wheels drive equally at all times, except when operating in TURF mode. This means that the outside wheel must travel a greater distance than the inside wheel when turning, and the inside tire must slip traction slightly. 1. Slow down. 2. Never turn quickly ...

70 OPERATION Driving with a Passenger 1. Make sure the passenger is at least 12 years of age and is tall enough to comfortably reach the footrests and grab han-dles. 2. Make sure the passenger is wearing appropriate riding gear, including an approved helmet with a rigid chin guard. See page 12. 3. P...

71 OPERATION Driving with a Passenger 10. Ride to the ability of your passenger, instead of to your own ability. Avoid unexpected or aggressive maneuvers that could cause a pas-senger to fall from the vehicle. 11. Do not cross a hillside with a passenger on board. See page 74. 12. A passenger should...

72 OPERATION Driving on Slippery Surfaces Whenever riding on slippery surfaces such as wet trails or loose gravel, or during freez-ing weather, follow these precautions: 1. Slow down when enter- ing slippery areas. 2. Engage AWD before wheels begin to lose traction. 3. Maintain a high level of alert...

73 OPERATION Driving Uphill Whenever traveling uphill, follow these precautions: 1. If your ATV is equipped with Active Descent Control, always engage AWD before ascending a hill. See page 49. 2. Drive straight uphill. 3. Avoid steep hills (15 ° maximum). 4. Keep both feet on the footrests. 5. Shift...

74 OPERATION Driving on a Sidehill (Sidehilling) Sidehilling can be dangerous and should be avoided if at all possible. If you encounter a situation where sidehilling is necessary, follow these precautions: 1. Slow down. 2. Do not cross a hillside with a passenger on board. Ask the passenger to dism...

75 OPERATION Driving Downhill When driving downhill, follow these precautions: 1. If your ATV is equipped with Active Descent Control, always engage AWD before descending a hill. See page 49. 2. Always descend a hill with the transmission in forward gear. Do not descend a hill with the transmission ...

77 OPERATION Turning Around on a Hill (K-Turn) 1. Stop and lock the parking brake while keeping body weight uphill. 2. If your ATV is equipped with Active Descent Control, engage AWD. See page 49. 3. Leave the transmission in forward and shut off the engine. 4. If a passenger is on board, ask the pa...

78 OPERATION Driving Through Water Your ATV can operate through water with a maximum recommended depth equal to the bottom of the footrests. Follow these procedures when operating through water: 1. Determine water depths and current before crossing. 2. Choose a crossing where both banks have gradual...

80 OPERATION Driving Over Obstacles 1. Be alert! Look ahead and learn to read the terrain you're traveling on. Be constantly alert for hazards such as logs, rocks and low hang-ing branches. 2. Avoid operating over large obstacles such as rocks and fallen trees when possible. If unavoidable, use extr...

81 OPERATION Parking on an Incline Avoid parking on an incline if possible. If it's unavoidable, follow these precautions: 1. Stop the engine. 2. Place the transmission in PARK. 3. Lock the parking brake. 4. Always block the rear wheels on the downhill side.

82 OPERATION Driving in Reverse WARNING Failure to use caution when operating in reverse can result in serious injury or death. Before shifting into reverse, always check for obstacles or people behind the vehicle. When it's safe to proceed, back slowly.Do not use the override switch unless addition...

83 OPERATION Driving in Reverse Follow these precautions when operating in reverse: 1. Always check for obstacles or people behind the vehicle. Be aware that a passenger can obstruct your view. 2. Always avoid backing downhill. 3. Back slowly. 4. Apply the brakes lightly for stopping. 5. Avoid turni...

84 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...

85 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...

86 MAINTENANCE Periodic Maintenance Chart Maintenance Chart Key X Perform these operations more often for vehicles subjected to severe use. E Emission-related service (Failure to conduct this maintenance will not void the emissions warranty but may affect emissions.) Q Have an authorized Polaris dea...

89 MAINTENANCE Lubrication Guide Check and lubricate all components at the intervals outlined in the Periodic Maintenance Chart beginning on page 85. Items not listed in the chart should be lubricated at the General Lubrication interval. NOTE: The a-arms and upper control arms are lubricated at the ...

90 MAINTENANCE Engine Oil Oil Recommendations Polaris Premium 4 All Season synthetic engine oil has been specially formulated for use in Polaris 4-cycle engines. It's a fully synthetic, high performance, multi-viscosity oil designed to provide the ultimate in lubrication performance and protection. ...

91 MAINTENANCE Engine Oil Oil Level (500 EFI) Access the oil dipstick and fill tube from the left side of the ATV. NOTE: A rising oil level between checks in cool weather driving can indicate contaminants such as gas or moisture col- lecting in the crankcase. If the oil level is over the full/safe m...

94 MAINTENANCE Engine Oil Oil and Filter Change (500 EFI) 12. Place shop towels beneath the oil filter. Using an oil filter wrench, turn the filter counterclockwise to remove it. 13. Make sure the o-ring from the old filter is completely removed from the engine. Using a clean dry cloth, clean the fi...

95 MAINTENANCE Engine Oil Oil and Filter Change (500 EFI) Oil Pump Priming This priming procedure must be performed whenever the oil hose connection between the oil tank and pump inlet has been disconnected. 1. Clamp or pinch off the vent line approximately 2" (5 cm) from the oil tank, between t...

96 MAINTENANCE Engine Oil Oil and Filter Change (800 EFI) Always change the oil and filter at the intervals outlined in the Periodic Maintenance Chart beginning on page 85. Always change the oil filter whenever changing oil. 1. Position the vehicle on a level surface. 2. Start the engine. Allow it t...

97 MAINTENANCE Engine Oil Oil and Filter Change (800 EFI 9. Place shop towels beneath the oil filter. Using an oil filter wrench (available from your Polaris dealer), turn the filter counter-clockwise to remove it. 10. Using a clean dry cloth, clean the filter sealing surface on the crankcase. 11. L...

98 MAINTENANCE Transmission Oil Always check and change the transmission oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 85. Maintain the oil level at the bottom of the fill plug hole threads. We recommend the use of Polaris Premium AGL Synthetic Gearcase Lubricant....

99 MAINTENANCE Transmission Oil Transmission Oil Change 1. Remove the fill plug. 2. Place a drain pan under the gearcase. 3. Remove the drain plug. Allow the oil to drain completely. 4. Clean and reinstall the drain plug. Torque to 20-25 ft. lbs. (27-34 Nm). 5. Add 32 oz. (948 ml) of the recommended...

100 MAINTENANCE Front Gearcase (Demand Drive) Fluid Fluid Level 1. Position the vehicle on a level surface. 2. Remove the fill plug. Check the fluid level. 3. Add the recommended demand drive fluid as needed to bring the level to the bottom of the fill hole threads. 4. Reinstall the fill plug. Torqu...

101 MAINTENANCE Active Descent Control (ADC) Fluid Fluid Level 1. Open the front box cover and pull open the access door. 2. View the fluid level in the reservoir. If the level is below the mini- mum mark, remove the cap and add the recommended fluid. 3. Reinstall the cap securely. Secure the access...

102 MAINTENANCE Cooling System The engine coolant level is controlled, or maintained, by the recovery system. The recovery system components are the recovery bottle, the radiator filler neck, the radiator pressure cap and the connecting hose. As coolant operating temperature increases, the expanding...

103 MAINTENANCE Cooling System Radiator Coolant To ensure that the coolant maintains its ability to protect the engine, Polaris recommends that you drain the system completely every two years and add a fresh mixture of antifreeze and water. Replace the coolant any time the cooling system has been dr...

104 MAINTENANCE Brakes Hand Brake The front and rear brakes are hydraulic disc brakes, activated by moving the single brake lever toward the handlebar. These brakes are self-adjusting. Under normal operation, the diaphragm extends into the reservoir as fluid level drops. If the fluid level is low an...

105 MAINTENANCE Toe Alignment Use the following procedure to check the toe alignment of the vehicle. The recommended toe alignment is 1/8" to 1/4" (3-6 mm) toe out. 1. Place the handlebars in a straight-ahead position. 2. Place stands in front of the vehicle, per-pendicular to the rear tires...

106 MAINTENANCE Steering Assembly The steering assembly of the ATV should be checked periodically for loose nuts and bolts. If loose nuts and bolts are found, see your Polaris dealer for service before operating the vehicle. Side Panel Removal 1. Remove the seat. 2. Grasp the rear of the side panel ...

107 MAINTENANCE Tires Refer to the specifications section beginning on page 144 for recom-mended tire type, size and pressure. Tire Tread Depth Always replace tires when tread depth is worn to 1/8" (3 mm) or less. Front Wheel Hub Tightening Front wheel bearing tightness and spindle nut retention...

108 MAINTENANCE Tires Wheel Installation 1. Place the transmission in PARK. 2. Lock the parking brake. 3. Place the wheel on the hub with the valve stem toward the outside and rotation arrows on the tire pointing toward forward rotation. 4. Install the wheel nuts and finger-tighten them. 5. Lower th...

109 MAINTENANCE Air Filter 1. Remove the seat. 2. Release the air box cover clips, and remove the air box cover. 3. Loosen the clamp and remove the filter. 4. Remove the fabric type pre-filter from the main filter. Wash the pre-filter in soapy water, then rinse and let dry. 5. Reinstall the pre-filt...

110 MAINTENANCE Breather Filter/Hose (500 EFI The breather filter is on the hose that runs between the engine and air box. 1. Remove the left side panel. See page 106. 2. Remove the hose clamps from the fil-ter and pull the filter out of the hoses. 3. Inspect the filter for debris. Blow gently throu...

111 MAINTENANCE Fuse Replacement (800 EFI) If the engine stops or will not start, or if you experience other electrical failures, a fuse may need replace-ment. NOTE: Spare fuses are provided in a compartment on the top of the access door. 1. Open the front box cover and pull open the access door. 2....

112 MAINTENANCE Lights When servicing a halogen lamp, don't touch the lamp with bare fingers. Oil from your skin leaves a residue, causing a hot spot that will shorten the life of the lamp. Headlight Lamp Replacement 1. Remove the two screws on the lower front corners of the headlight pod. 2. Remove...

113 MAINTENANCE Lights High Beam Adjustment The headlight beam can be adjusted slightly upward or downward. Use the following procedure to make the adjustment. 1. Position the vehicle on a level surface with the headlight approxi- mately 25 ft. (7.6 m) from a wall. Place the transmission in PARK. 2....

114 MAINTENANCE Lights Headlight Housing Replacement 1. Remove the two screws on the lower front corners of the headlight pod. 2. Lift the pod slightly while depressing the tabs at the rear of the pod. 3. Lift the pod cover and disconnect the speedometer harnesses from the speedometer. 4. Unplug the...

115 MAINTENANCE Lights Lower Headlamp Replacement 1. Turn the back of the headlight harness counterclockwise and pull the harness assembly away from the headlight assembly. 2. Remove the headlamp and install the new headlamp. 3. Reinstall the harness assembly into the headlight assembly. 4. Turn the...

116 MAINTENANCE Spark Plugs Spark Plug Recommendations Refer to the specifications section beginning on page 144 for the recom-mended spark plug type and gap for your vehicle. Torque spark plugs to specification. Spark Plug Inspection Spark plug condition is indicative of engine operation. Check the...

117 MAINTENANCE Spark Plugs Spark Plug Inspection Normal Spark Plug The normal insulator tip is gray, tan or light brown. There will be few combustion deposits. The electrodes are not burned or eroded. This indi-cates the proper type and heat range for the engine and the service. NOTE: The tip shoul...

118 MAINTENANCE Vehicle Immersion 1. If it's impossible to take your ATV to a dealer before starting it, fol- low the steps outlined below. 2. Move the ATV to dry land or at the very least, to water below the footrests. 3. Check the air box. If water is present, dry the air box and replace the filte...

119 MAINTENANCE Spark Arrestor Use the following procedure to periodically purge accumulated carbon from the exhaust pipe/muffler. 1. Remove the arrestor clean-out plug from the bottom of the muffler. 2. Place the transmission in PARK. 3. Start the engine. 4. Quickly squeeze and release the throttle...

120 MAINTENANCE 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...

122 MAINTENANCE PVT System When To Use Low Range and High Range PVT Drying There may be some instances when water is accidently ingested into the PVT system. Use the following instructions to dry it out before operat-ing. 1. Position the vehicle on a level surface. 2. Remove the drain plug. Allow th...

123 MAINTENANCE Battery Your ATV may have either a sealed battery, which requires little mainte-nance, or a conventional battery. A sealed battery can be identified by its flat covers on the top of the battery. A conventional battery has six filler caps on the top of the battery. Conventional Batter...

124 MAINTENANCE Battery Battery Removal 1. Disconnect the battery hold-down strap. 2. Remove the battery cover. 3. On conventional batteries, remove the battery vent tube. 4. Disconnect the black (negative) battery cable first. 5. Disconnect the red (positive) battery cable last. 6. Lift the battery...

125 MAINTENANCE Battery Battery Installation Using a new battery that has not been fully charged can damage the bat-tery and result in a shorter life. It can also hinder vehicle performance. Follow the battery charging instructions on page 127 before installing the battery. 1. Ensure that the batter...

126 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...

127 MAINTENANCE Battery Battery Charging (Conventional Battery) 1. Remove the battery from the vehicle to prevent damage from leak- ing or spilled electrolyte during charging. See page 124. 2. Charge the battery with a charging output no larger than 1/10 of the battery’s amp/hr rating. Charge as nee...

128 MAINTENANCE Battery Battery Charging (Sealed Battery) NOTE: Always verify battery condition before and 1-2 hours after the end of charging. State of Charge Voltage Action Charge Time (Using constant current charger @ standard amps specified on top of battery) 100% 12.8-13.0 volts None, check at ...

129 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. The best and safest way to clean your Polaris vehicle is with a garden hose and a pail of mild soap and water. 1. Us...

130 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 decals. Avoid directing the water stream at the follow-ing items: • Wheel bearings• Ra...

131 MAINTENANCE Cleaning and Storage Chrome Wheel Care (if equipped) Proper maintenance will protect chrome wheels from corrosion, pre-serve wheel life and ensure a "like new" appearance for many years. NOTE: Chrome wheels exposed to road salt (or salt in the air in coastal areas) are more s...

132 MAINTENANCE Cleaning and Storage Storage Tips Clean the Exterior Make any necessary repairs and clean the vehicle as recommended. See page 129. Stabilize the Fuel 1. Fill the fuel tank. 2. Add Polaris Carbon Clean Fuel Treatment or Polaris Fuel Stabilizer. Follow the instructions on the containe...

133 MAINTENANCE Cleaning and Storage Storage Tips Fluid Levels Inspect the fluid levels. Add or change fluids as recommended in the Periodic Maintenance Chart beginning on page 85.• Demand drive unit (front gearcase)• ADC fluid (ADC models) (change every two years)• Rear gearcase (if equipped)• Tran...

134 MAINTENANCE Cleaning and Storage Storage Tips Inspect and Lubricate Inspect all cables and lubricate all areas of the vehicle as recommended in the Periodic Maintenance Chart beginning on page 85. Battery Storage See pages 126-127 for storage and charging procedures. Storage Area/Covers Set the ...

135 MAINTENANCE Transporting the ATV Follow these procedures when transporting the vehicle. 1. Stop the engine. 2. Place the transmission in PARK. 3. Lock the parking brake. 4. Always secure the seat in the 1-up position to prevent loss during transporting. 5. Secure the fuel cap and oil cap. 6. Alw...

136 ADJUSTMENTS Camber and Caster The camber and caster are non-adjustable. Rear Spring The rear shock absorber spring is adjusted by rotating the adjuster either clockwise or counterclockwise to increase or decrease spring tension. NOTE: Accessory springs are available through your Polaris dealer. ...

137 ADJUSTMENTS Handlebars The handlebars can be adjusted for rider preference. 1. Remove the upper headlight pod. 2. Loosen the four handlebar bolts. 3. Adjust the handlebar to the desired height. NOTE: Be sure the handlebars do not contact the gas tank or any other part of the machine when turned ...

138 ADJUSTMENTS Throttle Body/Idle RPM Idle RPM is preset by the manufacturer. If the engine idle speed is not satisfactory, please see your Polaris dealer for adjustment. Throttle Cable Freeplay Adjust throttle cable freeplay at the handlebar. 1. Locate the throttle cable adjuster at the handlebar....

139 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 or turn around using the K-turn (see page 76). Driving at low RPM or ground speed (3-7 MPH) Drive at ...

140 TROUBLESHOOTING Engine Doesn't Turn Over Engine Turns Over, Fails to Start Engine Backfires 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 connections and tighten Possib...

141 TROUBLESHOOTING Engine Pings or Knocks Engine Runs Irregularly, Stalls or Misfires Possible Cause Solution Poor quality or low octane fuel Replace with recommended fuel Incorrect ignition timing See your dealer Incorrect spark plug gap or heat range Set gap to specs or replace plugs Possible Cau...

142 TROUBLESHOOTING Engine Stops or Loses Power Engine Overheating Possible Cause Solution Out of fuel Refuel, cycle key to ON position three times for 5 seconds each, then start Kinked or plugged fuel vent line Inspect and replace Water is present in fuel Replace with new fuel Fouled or defective s...

143 POLARIS PRODUCTS Part Number Description Engine Lubricant 2870791 Fogging Oil (12 oz. Aerosol) 2871281 Premium 4 Synthetic 0W-40 (4-Cycle) Engine Oil (qt./.95 l) 2871844 Premium 4 Synthetic 0W-40 (4-Cycle) Engine Oil (gal./3.8 l) Gearcase / Transmission Lubricants 2873602 Premium AGL Synthetic G...

144 SPECIFICATIONS * Based on EU Directive 76/432/EC Sportsman X2 500 EFI Gross Vehicle Weight 1500 lbs. (680 kg) Dry Weight 798 lbs. (362 kg) (base model) (weight of other models may vary) Front Rack/Storage Box Capacity 90 lbs. (41 kg)Rear Rack/Storage Box Capacity 400 lbs. (181 kg) Receiver Hitch...

148 WARRANTY LIMITED WARRANTY Polaris Sales Inc., 2100 Highway 55, Medina, MN 55340, gives a SIX MONTH LIM-ITED WARRANTY on all components of the Polaris All Terrain Vehicle (ATV) against defects in material or workmanship. Polaris also gives a one year limited warranty on the final drive chain for ...

149 WARRANTY WARRANTY COVERAGE AND EXCLUSIONS: LIMITATIONS OF WARRANTIES AND REMEDIES The Polaris limited warranty excludes any failures that are not caused by a defect in material or workmanship. This warranty does not cover accidental damage, normal wear and tear, abuse or improper handling. This ...

150 WARRANTY ALL IMPLIED WARRANTIES (INCLUDING BUT NOT LIMITED TO THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PAR-TICULAR PURPOSE) ARE LIMITED IN DURATION TO THE ABOVE SIX MONTH WARRANTY PERIOD. POLARIS FURTHER DISCLAIMS ALL EXPRESS WARRANTIES NOT STATED IN THIS WARRANTY. Some states...

151 WARRANTY Exported Vehicles EXCEPT WHERE SPECIFICALLY REQUIRED BY LAW, THERE IS NO WAR-RANTY OR SERVICE BULLETIN COVERAGE ON THIS VEHICLE IF IT IS SOLD OUTSIDE THE COUNTRY OF THE SELLING DEALER'S AUTHORIZED LOCA-TION.This policy does not apply to vehicles that have received authorization for expo...

152 WARRANTY Exported Vehicles How to Get Service If Purchased From A Private Party: If you purchase a Polaris product from a private citizen outside of the country in which the vehicle was originally purchased, all warranty coverage will be denied. Notice If your vehicle is registered outside of th...

154 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 ser-vices performed. DATE MILES (KM) OR HOURS TECHNICIAN SERVICE PERFORMED / COMMENTS

157 INDEX H Hand Brake . . . . . . . . . . . . . . . . . . . 104 Handlebar Adjustment . . . . . . . . . . 137 Hauling Cargo . . . . . . . . . . . . . . . 64-67 Headlight Housing Replacement . . 114 Headlight Lamp Replacement . . . . 112 Headlight Switch. . . . . . . . . . . . . . . . 39 Helmet. . . ...

156 INDEX A Accessories . . . . . . . . . . . . . . . . . . 134 Active Descent Control Fluid . 100-101 Active Descent Control System . . . . 49 Age Restrictions. . . . . . . . . . . . . . . . 14 Air Filter . . . . . . . . . . . . . . . . . . . . 109 All Wheel Drive System . . . . . . . 47-48 Auxilia...