Page 2 - WARNING; The engine exhaust from this product contains
WARNING The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects or other reproductive harm.
Page 5 - WELCOME; RANGER
1 WELCOME Thank you for purchasing a Polaris vehicle, and welcome to our world- wide family of Polaris owners. We proudly produce an exciting line of utility and recreational products. • Snowmobiles• All-terrain vehicles (ATVs)• RANGER ® utility vehicles • Victory Motorcycles ® We believe Polaris se...
Page 7 - TABLE OF CONTENTS
3 TABLE OF CONTENTS Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7Features and Controls . . . . . . . . . . . . . . . . . . . 26Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46Emis...
Page 8 - INTRODUCTION; CAUTION; NOTICE
4 INTRODUCTION 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 indicates a potential personal injury hazar...
Page 10 - Vehicle Identification Numbers; spaces provided. Remove the spare key and store it in a safe place. An
6 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 o...
Page 11 - SAFETY; Safety Training; encourages you and any family members who will be riding the ATV to; in the ATV; for a fee. Call ATV Enrollment Express at; FOR MORE INFORMATION ABOUT ATV SAFETY in the United
7 SAFETY Safety Training ATV safety training is a top priority for Polaris. Polaris strongly encourages you and any family members who will be riding the ATV to take a training course.If you purchased a new Polaris ATV in the United States, your dealer provided instruction to you about the authorize...
Page 12 - Safe Riding Gear; Helmet
8 SAFETY Safe Riding Gear Always wear appropriate clothing when riding this vehicle. Wear pro- tective 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 esta...
Page 13 - Eye Protection; Do not depend on eyeglasses or sunglasses for eye protection. When-; Gloves; Always wear long sleeves and long pants to protect arms and legs.; Equipment Modifications
9 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...
Page 14 - Operating Without Instruction
10 SAFETY Failure to operate the vehicle properly can result in a collision, loss of control, accident or overturn, which may result in serious injury or death. Heed all safety warnings outlined in this section of the owner’s manual. See the OPERATION section of the owner’s manual for proper operati...
Page 15 - Safety Warnings; Handling Gasoline; Exposure to Exhaust
11 SAFETY Safety Warnings Handling Gasoline 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 spa...
Page 16 - Protective Apparel
12 SAFETY Safety Warnings Protective Apparel Riding on this vehicle without wearing an approved helmet and protective eyewear increases the risk of a serious injuries in the event of an accident.Operator and passenger must always wear an approved helmet that fits properly and eye protection (goggles...
Page 17 - Operating on Pavement
13 SAFETY Safety Warnings Operating on Pavement Operating this vehicle on paved surfaces (including sidewalks, paths, parking lots and driveways) may adversely affect the handling of the vehicle and could result in loss of control and accident or overturn.Avoid operating the vehicle on pavement. The...
Page 18 - Physical Control of the Vehicle
14 SAFETY Safety Warnings Physical Control of the Vehicle Removing a hand from the handlebars or feet from the footrests during operation can reduce your ability to control the vehicle or cause loss of balance and ejection from the vehicle. If the operator's foot is not firmly planted on the footres...
Page 19 - Descending Hills Improperly
15 SAFETY Safety Warnings Descending Hills Improperly Improperly descending a hill could cause loss of control or overturn.• Always follow proper procedures for travel- ing down hills as described in the owner's manual. NOTE: A special technique is required when braking while traveling down- hill. S...
Page 20 - Stalling While Climbing a Hill
16 SAFETY Safety Warnings Stalling While Climbing a Hill Stalling, rolling backwards or improperly dismounting while climbing a hill could cause an overturn.• Always maintain a steady speed when climbing a hill. • Always move the 4X4 switch to ADC 4X4 (if equipped) before ascending or descending a h...
Page 21 - Operating on Steep Hills
17 SAFETY Safety Warnings Operating on Steep Hills Operating on excessively steep hills could cause an overturn.Never operate on hills too steep for the vehicle or for your abilities. Never operate the vehicle on hills steeper than 25 degrees. Operating on Slippery Terrain Failure to use extra cauti...
Page 22 - Improper Tire Maintenance; Operating Over Obstacles
18 SAFETY Safety Warnings Improper Tire Maintenance Operating this vehicle with improper tires or with improper or uneven tire pressure could cause loss of control or accident.Always use the size and type of tires specified for your vehicle.Always maintain proper tire pressure as described in the ow...
Page 23 - Improper Cargo Loading
19 SAFETY Safety Warnings Improper Cargo Loading Overloading the vehicle or carrying/towing cargo improperly may cause changes in handling, which could cause loss of control or an accident.• Never exceed the stated load capacity for this vehicle. • Cargo should be properly distributed and securely a...
Page 24 - Operating Through Deep Water
20 SAFETY Safety Warnings Operating Through Deep Water Operating the vehicle through deep or fast-flowing water could cause the tires to float, causing loss of control or overturn.Avoid operating the vehicle through deep or fast-flowing water. If it's unavoidable to enter water that exceeds the reco...
Page 25 - Operating a Damaged Vehicle; Hot Exhaust Systems
21 SAFETY Safety Warnings Operating a Damaged Vehicle Operating a damaged vehicle can result in an accident. After any overturn or accident, have a qualified service dealer inspect the entire machine for possible damage, including (but not limited to) brakes, throttle and steering systems. Physical ...
Page 26 - Safety Labels and Locations; tact your Polaris dealer to purchase a replacement. Replacement; General Warning
22 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 instructi...
Page 27 - Tire Pressure/Load Warning
23 SAFETY Safety Labels and Locations Tire Pressure/Load Warning WARNINGImproper tire pressure or overloading can cause loss of control. Loss of control can result in severe injury or death.• Cold tire pressure: Front: 7.0 psi (48.3 kPa) Center: 10.0 psi (68.9 kPa)Rear: 10.0 psi (68.9 kPa) • Maximum...
Page 28 - Container/No Passenger Warning
24 SAFETY Safety Labels and Locations Container/No Passenger Warning WARNINGRemove flammable containers from box before refueling.WARNING• Passengers can be thrown off. This can cause serious injury or death.• Never carry passengers.Maximum Box Load 800 lbs. (363 kg) 7079316 + Clutch Cover Warning +...
Page 29 - Age 16 Warning; Hitch Capacity Label
25 SAFETY Safety Labels and Locations Age 16 Warning WARNINGOperating this ATV if you are under the age of 16 increases your chance of severe injury or death.NEVER operate this ATV if you are under age 16. 7172588 Clutch Cover Warning WARNING• Moving parts hazard under belt-clutch guard. To prevent ...
Page 30 - FEATURES AND CONTROLS; Switches; Mode/Reverse Override Switch; See page 34 for AWD information.
26 FEATURES AND CONTROLS Switches Mode/Reverse Override Switch This vehicle is equipped with a reverse speed limiter system.To gain additional wheel speed while backing, release the throttle and depress the override button. WARNING! Pressing the override button while the throttle is open can cause l...
Page 31 - Engine Stop Switch
27 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. Both the main switch and the engine stop switch will shut off all electri- cal power to the vehicle,...
Page 32 - Throttle Lever
28 FEATURES AND CONTROLS Throttle Lever Operating this vehicle with sticking or improperly operating throttle controls could cause an accident. Never start or operate the vehicle if it has a sticking or improperly operating throttle. Always contact your dealer for service before operating the vehicl...
Page 33 - Brake Systems; middle axle rear brake only.
29 FEATURES AND CONTROLS Brake Systems Aggressively applying the rear brake when backing down a hill may cause rear tipover, which could result in serious injury or death. Never back down a hill.Use caution when applying the rear brake. Do not aggressively apply the rear brake when going forward. Th...
Page 34 - Service Brake Lever; reduce
30 FEATURES AND CONTROLS Brake Systems Service Brake Lever Squeeze the service brake lever (left lever) toward the handlebar to apply the front and rear brakes. These brakes are hydraulically acti- vated disc brakes.Always test brake lever travel and master cylinder fluid level before riding. When s...
Page 35 - Master Cylinder/Brake Fluid; If the fluid level is low add DOT 4 brake fluid only. Do not overfill.
31 FEATURES AND CONTROLS Master Cylinder/Brake Fluid An over-full master cylinder may cause brake drag or brake lock-up, which could result in an accident. Maintain brake fluid at the recommended level. Do not overfill.Never store or use a partial bottle of brake fluid. Brake fluid is hygroscopic, m...
Page 36 - Parking Brake; Locking the Parking Brake
32 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 ...
Page 37 - Automatic Transmission Gear Selector; Belt Life; Fuel Tank Cap; Do not use
33 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: ParkTo shift gears, brake to a complete stop. When the engine is idling, move the lever to the desired gear. NOTICE:...
Page 38 - AWD Mode
34 FEATURES AND CONTROLS All Wheel Drive (AWD) System The All Wheel Drive system is controlled by the 4X4 (AWD) switch. ADC 4X4 Mode (if equipped) When the switch is on ADC 4X4, the ADC system allows engine braking to all six wheels when the vehicle descends a hill or incline. Always move the 4X4 sw...
Page 39 - All Wheel Drive System; Engaging AWD; The 4X4 switch may be turned on or off while the vehicle is moving.
35 FEATURES AND CONTROLS All Wheel Drive System Engaging AWD The 4X4 switch may be turned on or off while the vehicle is moving. Initially, the vehicle's electronic system will not enable AWD until the engine RPM is below 3100. Once enabled, AWD remains enabled until the 4X4 switch is turned off. If...
Page 40 - when the vehicle descends a hill or incline. Always move the 4X4; Engaging Active Descent Control; The ADC system will automatically engage when; Disengaging Active Descent Control; The ADC system will automatically disengage if
36 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. Always move the 4X4 switch to ADC 4X4 before ascending or descending a hill. Engaging Active Descent Control The ADC system ...
Page 41 - Instrument Cluster; 6 for additional information.
37 FEATURES AND CONTROLS Instrument Cluster Your vehicle is equipped with an instrument cluster that senses vehicle speed from the right front wheel. In addition to showing vehicle speed, the speedometer needle flashes when a warning condition exists.The instrument cluster measures distance in miles...
Page 42 - Rider Information Center
38 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. If the instrument cluster fails to illuminate, a battery over-voltage may have occurred and the instrument...
Page 43 - Standard Modes; Use the MODE button to toggle through the mode options. The reverse; Odometer Mode; The odometer records the miles traveled by the vehicle.; Trip Meter Mode; This mode logs the total hours the engine has been in operation.; Tachometer Mode; from day to day may be normal because of changes in humidity, temper-
39 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 26. The transmission cannot be in reverse when using this feature. Odometer Mode The odometer reco...
Page 44 - Diagnostic Mode; To exit the diagnostic mode, turn the key switch off and on. Any move-
40 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...
Page 45 - View this screen to check battery voltage level.; Tachometer Screen; View the tachometer to check engine speed.; X4 Diagnostic Screen; see your dealer for all major repairs.; Gear Circuit Diagnostic Screen; only. Please see your dealer for all major repairs.; Programmable service interval; When the hours of engine operation equal the programmed service
41 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 throug...
Page 46 - hold; Miles/Kilometers toggle
42 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...
Page 47 - Downloading Codes; ing procedure to download blink codes (failure codes) from the EFI
43 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 45 for Blink Codes and Failure Descriptions. Use the follow- ing procedure to download bli...
Page 50 - OPERATION
46 OPERATION Failure to operate the vehicle properly can result in a collision, loss of control, accident or overturn, 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...
Page 51 - Engine and Drivetrain Break-in
47 OPERATION Break-In Period Engine and Drivetrain Break-in 1. Fill the fuel tank with gasoline. See page 33. Always exercise extreme caution whenever handling gasoline. 2. Check the engine oil level on the dipstick. See page 72. Add oil if necessary to maintain the level between the safe and add ma...
Page 52 - Item
48 OPERATION Pre-Ride Checklist Failure to inspect and verify that the vehicle is in safe operating condi- tion before operating increases the risk of an accident. Always inspect the vehicle before each use to make sure it's in safe operating condition. Item Remarks Page Brake system/lever travel En...
Page 53 - Safe Operation Practices
49 OPERATION Safe Operation Practices 1. Complete the recommended safety training before operating this vehicle. See page 7. 2. Do not allow anyone under 16 years of age to operate this vehicle. Do not allow anyone with cognitive or physical disabilities to oper- ate this vehicle. 3. Never carry a p...
Page 54 - Know Your Riding Area/Tread Lightly; terrain, avoid littering, and always stay on the designated trails.; Trail Etiquette; Always practice good etiquette when riding. Allow a safe distance
50 OPERATION Know Your Riding Area/Tread Lightly Familiarize yourself with all laws and regulations concerning the opera- tion of this off-road vehicle in your area. Respect the environment in which you ride. Find out where the designated riding areas are by con- tacting your Polaris dealer, a local...
Page 55 - Starting the Engine; Cold Weather Operation
51 OPERATION Starting the Engine 1. Position the vehicle on a level surface outdoors or in a well-venti- lated area. 2. Place the transmission in park.3. Lock the parking brake. Tip: The starter interlock will prevent the engine from starting if the transmission is in gear and the brake is not engag...
Page 56 - Driving Procedures; brakes on level surfaces.
52 OPERATION Driving Procedures 1. Wear a helmet and eye protection. See page 8.2. Sit upright with both feet on the footrests and both hands on the handlebars. 3. Start the engine and allow it to warm up. 4. Shift the transmission into gear.5. Check your surroundings and determine your path of trav...
Page 57 - Turning the Vehicle
53 OPERATION Turning the Vehicle Your vehicle is equipped with a solid rear axle, which drives both rear wheels equally at all times. This means that the wheel on the outside of the turn must travel a greater distance than the inside wheel when turn- ing and the inside tire must slip traction slight...
Page 58 - Driving on Slippery Surfaces; Never apply the brakes during a skid. Correct a skid by turning the
54 OPERATION Driving on Slippery Surfaces Whenever riding on slippery surfaces such as wet trails or loose gravel, or during freezing weather, follow these precautions:1. Do not operate on excessively rough, slippery or loose terrain.2. Slow down when entering slippery areas.3. Engage 4X4 before whe...
Page 59 - Driving Uphill; ascending or descending a hill. See page 36.
55 OPERATION Driving Uphill Braking and handling are greatly affected when operating in hilly ter- rain. Improper procedure could cause loss of control or overturn. When- ever traveling uphill, follow these precautions:1. Always move the 4X4 switch to ADC 4X4 (if equipped) before ascending or descen...
Page 60 - unavoidable
56 OPERATION Driving on a Sidehill (Sidehilling) Driving on a sidehill is not recommended. Improper procedure could cause loss of control or overturn. Avoid crossing the side of any hill unless absolutely necessary.If crossing a sidehill is unavoidable , follow these precautions: 1. Slow down.2. Avo...
Page 61 - Driving Downhill
57 OPERATION Driving Downhill When driving downhill, follow these precautions:1. Always move the 4X4 switch to ADC 4X4 (if equipped) before ascending or descending a hill. See page 36. 2. Avoid steep hills (25 ° maximum). 3. Shift body weight uphill.4. Drive straight downhill.5. Slow down. Excessive...
Page 63 - Driving Through Water; If it’s unavoidable to enter water deeper than the footrest level:
59 OPERATION Driving Through Water Your vehicle can operate through water with a maximum recommended depth equal to the bottom of the footrests. Fol- low these procedures when operating through water:1. Determine water depths and current before entering water. 2. Choose a crossing where both banks h...
Page 64 - Driving Over Obstacles; ards such as logs, rocks and low hanging branches.
60 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 haz- ards such as logs, rocks and low hanging branches. 3. Travel slowly and us...
Page 65 - Driving in Reverse; lightly
61 OPERATION Driving in Reverse Follow these precautions when operating in reverse:1. Always check for obstacles or people behind the vehicle.2. Always avoid backing downhill.3. Back slowly.4. Apply the brakes lightly for stopping. 5. Avoid turning at sharp angles.6. Never open the throttle suddenly...
Page 66 - Hauling Cargo; Maximum Towing Capacities
62 OPERATION Hauling Cargo Overloading the vehicle or carrying or towing 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 c...
Page 68 - Dumping Cargo; Select a level site to dump the cargo.
64 OPERATION Hauling Cargo Dumping Cargo 1. Select a level site to dump the cargo. Do not attempt to dump or unload the vehicle while parked on an incline. 2. Lock the parking brake.3. Dismount the vehicle.4. Check cargo distribution. If cargo has shifted to the rear of the box, exercise caution. WA...
Page 69 - Parking on an Incline
65 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.
Page 70 - EMISSION CONTROL SYSTEMS; Noise Emission Control System; Do not modify the engine, intake or exhaust components, as doing so; Crankcase Emission Control System; are forced back to the combustion chamber by the intake system. All; Exhaust Emission Control System; ponents are set at the factory for optimal performance and are not; Electromagnetic Interference
66 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...
Page 71 - MAINTENANCE; Periodic Maintenance Chart; serviced more frequently.; Severe Use Definition; cause or see your dealer.
67 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 part...
Page 72 - Maintenance Chart Key; not void the emissions warranty but may affect emissions.)
68 MAINTENANCE Periodic Maintenance Chart Improperly performing the procedures marked with a could result in component failure and cause an accident, which may result in serious injury or death. Always have an authorized Polaris dealer perform these services. Maintenance Chart Key X Perform these ...
Page 75 - Lubrication Recommendations
71 MAINTENANCE Lubrication Recommendations Check and lubricate all components at the intervals outlined in the Peri- odic Maintenance Chart beginning on page 67. Items not listed in the chart should be lubricated at the General Lubrication interval.The a-arms and lower control arms are lubricated at...
Page 76 - Engine Oil; Oil Recommendations; PLUS; Oil Level
72 MAINTENANCE Engine Oil Oil Recommendations Polaris recommends the use of Polaris PS-4 PLUS Performance Syn- thetic 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 recommendat...
Page 77 - Oil and Filter Change
73 MAINTENANCE Engine Oil Oil and Filter Change Always change the oil and filter at the intervals outlined in the Periodic Maintenance Chart beginning on page 67. Always change the oil filter whenever changing oil.1. Position the vehicle on a level surface.2. Start the engine. Allow it to warm up at...
Page 78 - Check to make sure the o-ring is in good condition.
74 MAINTENANCE Engine Oil Oil and Filter Change 10. Lubricate the o-ring on the new filter with a film of fresh engine oil. Check to make sure the o-ring is in good condition. 11. Install the new filter and rotate it clockwise by hand until the filter gasket contacts the sealing surface, then turn i...
Page 79 - Transmission Oil; Oil Check
75 MAINTENANCE Transmission Oil Always check and change the transmission oil at the intervals outlined in the Periodic Mainte- nance Chart beginning on page 67. Maintain the oil level at the bottom of the fill plug hole. The fill plug is located on the right side of the ATV behind the footwell. The ...
Page 80 - Fluid Check; Demand Drive Capacities
76 MAINTENANCE Front Gearcase (Demand Drive) Fluid Always check and change the demand drive fluid at the intervals out- lined in the Periodic Maintenance Chart beginning on page 67. We rec- ommend the use of Polaris Demand Drive Plus Fluid. Use of other fluids may result in improper operation of com...
Page 81 - Fluid Change
77 MAINTENANCE Front Gearcase (Demand Drive) Fluid Fluid Change 1. Position the vehicle on a level surface. Remove the fill plug.2. Place a drain pan under the demand drive unit. 3. Remove the drain plug. Allow the fluid to drain completely. 4. Clean and reinstall the drain plug. Torque to 11 ft. lb...
Page 82 - Rear Gearcase Oil; Oil Change; Do not overfill
78 MAINTENANCE Rear Gearcase Oil Always check and change the rear gearcase oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 67. Maintain the fluid level at the bottom of the fill hole threads. The oil capacity is 5 oz. (150 ml). Do not overfill.The fill plug is locat...
Page 83 - Middle Gearcase Oil
79 MAINTENANCE Middle Gearcase Oil Always check and change the mid- dle gearcase oil at the intervals outlined in the Periodic Mainte- nance Chart beginning on page 67.We recommend the use of Polaris ATV Angle Drive Fluid (or GL5 80-90 weight gear lube). See page 124 for the part numbers of Polaris ...
Page 86 - Cooling System; Recovery Bottle Coolant
82 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 (...
Page 87 - Radiator Coolant
83 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 drai...
Page 88 - Brakes
84 MAINTENANCE Brakes Front/Rear/Middle Brakes The front, rear and middle brakes are hydraulic disc brakes. These brakes are self-adjusting.Under normal operation, the diaphragm extends into the reservoir as fluid level drops. If the fluid level is low and the diaphragm is not extended, a leak is li...
Page 89 - Toe Alignment
85 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. WARNING! Severe injury or death can result from improper toe alignment and adjustment. Do not attempt to adjust tie rod alignmen...
Page 90 - Steering Assembly
86 MAINTENANCE Steering Assembly The steering assembly of the vehicle 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 pane...
Page 91 - Tires; Tire Tread Depth; Always replace tires; Front Wheel Hub Tightening
87 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...
Page 92 - Wheel Installation; and rotation arrows on the tire pointing toward forward rotation.; Wheel Nut Torque Specifications; ened for maintenance service.; Nut Type; Cast Aluminum
88 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 the ve...
Page 93 - Air Filter
89 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-filter...
Page 94 - Fuse Replacement; Fuse
90 MAINTENANCE Fuse Replacement If the engine stops or will not start, or if you experience other electrical failures, a fuse may need replace- ment. Locate and correct any short circuits that may have caused the blown fuse, then replace the fuse. Spare fuses are provided in a com- partment on the t...
Page 95 - Lights; lights are adjusted properly for best visibility.; Upper Headlight Lamp Replacement; Unplug the headlamp from the wiring harness. Be sure to pull on the
91 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. Always make sure lights are adjusted properly for best visibility. Upper Headlight La...
Page 96 - High Beam Adjustment; and make a mark on the wall at the same height.
92 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. M...
Page 97 - Low Beam Adjustment; The low beam can be adjusted
93 MAINTENANCE Lights Low Beam Adjustment The low beam can be adjusted slightly upward or downward.1. Loosen the phillips screw located at the rear of the headlamp. 2. Tilt the headlamp upward or downward. 3. Tighten the screw. Phillips Screw
Page 98 - Headlight Housing Replacement
94 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 h...
Page 99 - Lower Headlamp Replacement
95 MAINTENANCE Lights Lower Headlamp Replacement 1. Turn the back of the headlight harness counter-clockwise 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...
Page 100 - Spark Plugs; Spark Plug Recommendations; Spark Plug Inspection; spark plug counter-clockwise to remove it.; Plug Condition
96 MAINTENANCE Spark Plugs Spark Plug Recommendations Refer to the specifications section beginning on page 122 for the recom- mended spark plug type and gap for your vehicle. Torque spark plugs to specification. NOTICE: Using non-recommended spark plugs can result in serious engine damage. Always u...
Page 101 - Normal Spark Plug; end. There may be a carbon layer over the entire nose. Generally, the
97 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.The tip should not b...
Page 102 - Vehicle Immersion; filter with a new filter.
98 MAINTENANCE Vehicle Immersion If your vehicle becomes immersed, major engine damage can result if the machine is not thoroughly inspected. Take the vehicle to your dealer before starting the engine. If it's impossible to take your vehicle to a dealer before starting it, follow the steps outlined ...
Page 103 - Spark Arrestor
99 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 ...
Page 104 - PVT System
100 MAINTENANCE 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 precision balanced. Any modific...
Page 105 - force exerted on the movable drive sheave by the flyweights also
101 MAINTENANCE PVT System The basic operation of the Polaris PVT system is dependent on engine speed and vehicle torque requirements. As engine speed increases, the force exerted on the movable drive sheave by the flyweights also increases. This, in turn, increases the amount of pinch applied to th...
Page 106 - When To Use Low Range and High Range; stall the drain plug.; Condition
102 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 the...
Page 107 - Battery; cleaning solution or tap water into a conventional battery.
103 MAINTENANCE Battery 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. Ba...
Page 108 - Battery Removal; tional battery sideways, which could spill electrolyte.
104 MAINTENANCE Battery Battery Removal 1. Remove the seat.2. Disconnect the battery hold-down strap.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 out of the ve...
Page 109 - Battery Installation; teries do not have a vent tube). The vent tube must be free of
105 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 107 before installing the battery.1. Ensure that the batter...
Page 110 - Battery Storage
106 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...
Page 111 - fully charged
107 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 104. 2. Charge the battery with a charging output no larger than 1/10 of the battery’s amp/hr rating. Charge as nee...
Page 112 - State of
108 MAINTENANCE Battery Battery Charging (Sealed Battery) Always verify battery condition before and 1-2 hours after the end of charging. State of Charge Voltage Action Charge Time (Using constant current charger @ standard amps specified on top of battery) 100% 12.8-13.0 volts None, check at 3 mos....
Page 113 - Cleaning and Storage; Washing the Vehicle; but it can also extend the life of various components.; and the lower parts last.; Washing Tips
109 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 h...
Page 114 - safety; Polishing the Vehicle; Polishing Tips
110 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: If an informational...
Page 115 - Removing Corrosion
111 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. Chrome wheels exposed to road salt (or salt in the air in coastal areas) are more suscep...
Page 116 - Storage Tips; Clean the Exterior; Follow the instructions on the container for the recommended; Oil and Filter
112 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 then clean the vehic...
Page 117 - Fluid Levels
113 MAINTENANCE Cleaning and Storage Storage Tips Fluid Levels Inspect the following fluid levels. Change fluids as recommended in the Periodic Maintenance Chart beginning on page 67.• Demand drive unit (front gearcase)• ADC fluid (ADC models) (change every two years)• Rear gearcase• Middle gearcase...
Page 118 - Inspect and Lubricate; in the Periodic Maintenance Chart beginning on page 67.; Battery Maintenance; may promote corrosion and oxidation.; Accessories
114 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 67. Battery Maintenance Remove the battery and recharge it as outlined on page 107. Store the battery i...
Page 119 - Transporting the Vehicle
115 MAINTENANCE Transporting the Vehicle Follow these procedures when transporting the vehicle.1. Stop the engine.2. Place the transmission in park. 3. Lock the parking brake.4. Secure the fuel cap, oil cap and seat. 5. Always tie the frame of the vehicle to the transporting unit securely with suita...
Page 120 - ADJUSTMENTS; Camber and Caster
116 ADJUSTMENTS Camber and Caster The camber and caster are non-adjustable. Rear Springs The rear shock absorber springs are adjusted by rotating the adjusters either clockwise or counter-clockwise to increase or decrease spring tension. Always adjust all rear springs to equal settings.Accessory spr...
Page 121 - Throttle Body/Idle RPM
117 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. ...
Page 122 - TROUBLESHOOTING; Possible Cause
118 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 58). Driving at low RPM or ground speed (3-7 MPH) Drive at ...
Page 123 - Engine Doesn't Turn Over
119 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...
Page 124 - Engine Pings or Knocks
120 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...
Page 125 - Engine Stops or Loses Power
121 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...
Page 126 - SPECIFICATIONS
122 SPECIFICATIONS * Based on EU Directive 76/432/EC SPORTSMAN BIG BOSS 6X6 800 EFI Maximum Weight Capacity 1115 lbs. (507 kg) (includes operator, cargo, accessories) Fuel Capacity 4.1 gal. (15.5 l) Engine Oil Capacity 2 qts. (1.9 l) Coolant Capacity 3.6 qts. (3.4 l) Demand Drive Fluid Capacity 9.3 ...
Page 127 - Clutching
123 SPECIFICATIONS Clutching *EBS models require no helix/spring adjustment SPORTSMAN BIG BOSS 6X6 800 EFI Transmission Automatic PVT with E-Z Shift H/L/N/R/P Gear Reduction, Low 7.49:1 Gear Reduction, Reverse 5.11:1 Gear Reduction, High 3.05:1 Drive Ratio, Front 3.82:1 Drive Ratio, Final 3.10:1 Tir...
Page 128 - POLARIS PRODUCTS; Description
124 POLARIS PRODUCTS Part Number Description Engine Lubricant 2870791 Fogging Oil (12 oz. Aerosol) 2876244 PS-4 PLUS Performance Synthetic 2W-50 4-Cycle Oil (qt.) 2876245 PS-4 PLUS Performance Synthetic 2W-50 4-Cycle Oil (gal.) Gearcase / Transmission Lubricants 2873602 Premium AGL Synthetic Gearcas...
Page 129 - DECLARATION OF CONFORMITY
125 DECLARATION OF CONFORMITY Polaris Industries Inc., 2100 Hwy 55, Medina, MN 55340 U.S.A.Telephone 763-542-0500 We, Polaris Industries Inc., declare that the vehicles listed below conform to the essential health and safety requirements applicable to off-road all-terrain vehicles. PRODUCT IDENTIFIC...
Page 130 - WARRANTY; LIMITED WARRANTY
126 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 Light Utility Vehicle against defects in material or workmanship. Polaris also gives a one year limited warranty on the final drive chain (if equ...
Page 131 - WARRANTY COVERAGE AND EXCLUSIONS:
127 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 ...
Page 132 - LIMITATIONS OF WARRANTIES AND REMEDIES
128 WARRANTY LIMITATIONS OF WARRANTIES AND REMEDIES This warranty also excludes failures resulting from improper lubrication; improper engine timing; improper fuel; surface imperfections caused by external stress, heat, cold or contamination; operator error or abuse; improper component alignment, te...
Page 133 - HOW TO OBTAIN WARRANTY SERVICE; SPARK ARRESTOR
129 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 state...
Page 134 - Exported Vehicles; How to Get Service
130 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 ex...
Page 135 - Notice
131 WARRANTY Exported Vehicles How to Get Service If Purchased From A Private Party: If you purchase a Polaris product from a private citizen, to be kept and used outside of the country in which the vehicle was originally purchased, all warranty coverage will be denied. Notice If your vehicle is reg...
Page 138 - MAINTENANCE LOG
134 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
Page 141 - INDEX
137 INDEX 0-9 4X4 (AWD) Switch . . . . . . . . . . 26, 34 A Accessories . . . . . . . . . . . . . . . . . . . 114 Active Descent Control Fluid . . . 80-81 Active Descent Control System . . . . 36 ADC System . . . . . . . . . . . . . . . . . . . 36 Air Filter . . . . . . . . . . . . . . . . . . . . ....