Polaris Sportsman Forest 500, Owner'S Manual For Maintenance And Safety

Page 1: ...Manual for Maintenance and Safety Read this manual carefully It contains important safety information This is an adult vehicle only Operation is prohibited for those under 16 years of age Sportsman Fo...

Page 2: ...aler call 1 800 POLARIS or visit www polarisindustries com Polaris Sales Inc 2100 Hwy 55 Medina MN 55340 Phone 1 888 704 5290 Part No 9923430 Rev 01 Printed in USA 9923430 Before you operate this vehi...

Page 3: ...es Always follow the instructions and recommendations in this manual The manual contains instructions for minor maintenance but informa tion about major repairs is outlined in the POLARIS Service Manu...

Page 4: ...ies may result between the actual vehicle and the information presented in this publi cation Depictions and or procedures in this publication are intended for reference use only No liability can be ac...

Page 5: ...ntroduction 4 Safety 7 Features and Controls 34 Operation 51 Winch Guide 56 Emission Control Systems 62 Maintenance 63 Specifications 120 POLARIS Products 122 Troubleshooting 123 Warranty 127 Maintena...

Page 6: ...rdous situation which if not avoided will result in death or serious injury WARNING A WARNING indicates a hazardous situation which if not avoided may result in death or serious injury CAUTION A CAUTI...

Page 7: ...OLARIS dealer or visit the POLARIS web site at www polarisindustries com Age Restrictions This vehicle is an ADULT VEHICLE ONLY Operation is prohibited for anyone under 16 years of age Restrictions Th...

Page 8: ...r key number and mating it with one of your existing keys The ignition switch must be replaced if all keys are lost Vehicle Model Number ___________________________________________________ Frame VIN _...

Page 9: ...hicle Never operate this vehicle without proper instruction Take a training course Beginners should receive training from a certified instructor Never permit others to operate the vehicle unless they...

Page 10: ...or face shield gloves boots long sleeves and long pants Never consume alcohol or drugs before or while operating this vehicle Never operate at excessive speeds Travel and turn at speeds appropriate f...

Page 11: ...maintenance procedures outlined in this manual See page 53 Keep both hands on the handlebars Keep your feet on the footrests Always travel slowly when operating on unfamiliar terrain Use extra caution...

Page 12: ...maller hills before attempting larger hills Avoid climbing hills steeper than 25 Always follow the procedures outlined in this manual for driving on hills See page 22 Always follow the procedures outl...

Page 13: ...follow the procedures outlined in this manual for operating over obstacles See page 21 Always follow the procedures outlined in this manual for operating on slippery or loose surfaces Use extra cauti...

Page 14: ...er modify this POLARIS vehicle through improper installation or use of accessories Never exceed the stated load capacity for your vehicle Cargo must be properly distributed and securely attached Reduc...

Page 15: ...nd could result in loss of control Avoid sudden turns or swift movement of the handlebars Always remove the ignition key when the vehicle is not in use to prevent unauthorized use or accidental starti...

Page 16: ...ent safety labels are provided by POLARIS at no charge The part number is printed on the label The following pages repeat the information found on each label General Alert Multi Lingual Before you ope...

Page 17: ...oading information Clutch Cover Alert NO STEP Rack Warning Front and Rear WARNING DO NOT TOW FROM RACK OR BUMPER Vehicle damage or tipover may result causing severe injury or death Tow only from tow h...

Page 18: ...bear a U S Department of Transportation DOT label Approved helmets in Europe Asia and Oceania bear the ECE 22 05 label The ECE mark consists of a circle surrounding the letter E followed by the distin...

Page 19: ...sonal Protective Equipment PPE bearing markings such as VESC 8 V 8 Z87 1 or CE Make sure protective eye wear is kept clean Gloves Off road style gloves with knuckle pads are the best for comfort and p...

Page 20: ...the brakes 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 travel 6 Release the brakes 7 Slowly squeeze the throttle...

Page 21: ...n 2 Steer in the direction of the turn leaning your upper body to the inside of the turn while supporting your weight on the outer footrest Use the same leaning technique for turning in reverse 3 Prac...

Page 22: ...the trail Avoid quick sharp turns Tip To correct a rear wheel skid turn the handle bars in the same direc tion as the skid and shift body weight forward NOTICE Severe damage to the drive train may oc...

Page 23: ...Serious injury or death can result if your vehicle comes in contact with a hidden obstacle 2 Be alert Watch the terrain Use extra caution 3 Never operate over large obstacles 4 Avoid hazards such as l...

Page 24: ...ively slippery or loose surfaces 4 Shift your weight uphill 5 Drive straight uphill 6 Keep your feet on the footrests 7 Drive at a steady rate of speed to avoid stalling 8 Be alert Be prepared to take...

Page 25: ...fully stopped lock the hydraulic parking brake See page 39 Dismount on the uphill side or to either side if the vehicle is pointed straight uphill Turn the vehicle around using the K Turn See page 26...

Page 26: ...uphill 4 Avoid crossing the sides of steep hills 5 Keep your feet on the footrests 6 Steer slightly into the hill 7 If the vehicle begins to tip quickly turn the front wheels downhill if possible or d...

Page 27: ...void driving downhill at an angle which can cause the vehicle to pitch sharply to one side Drive straight downhill 6 Shift your weight rearward 7 Apply the brakes slightly to aid in slowing Always fol...

Page 28: ...ake 3 Leave the transmission in forward gear Turn the engine off 4 Dismount on the uphill side of the vehicle or on the left if the vehi cle is pointing straight uphill 5 Stay uphill of the vehicle an...

Page 29: ...12 Squeeze and release the brake lever to release the parking brake 13 Release the foot brake and drive slowly downhill Control speed with either the hand or foot brake until the vehicle is on level g...

Page 30: ...wly balance your weight carefully and avoid sudden movements Maintain a slow and steady forward motion Do not make sudden turns stops or throttle changes 3 Choose a crossing where both banks have grad...

Page 31: ...by your dealer promptly If water has been ingested into the transmission PVT follow the pro cedure on page 105 Always follow the procedures outlined in this manual for driving through water Never driv...

Page 32: ...Parking on an Incline Avoid parking on an incline If it s unavoidable follow these precau tions 1 Stop the engine 2 Place the transmission in PARK 3 Always block the rear wheels on the downhill side 4...

Page 33: ...o not use the override switch unless additional power is required for vehicle movement Use with caution Tip Reverse speed is greatly increased when the override switch is used Do not operate at full t...

Page 34: ...tion CARRYING A LOAD on only one rack may cause the vehicle to overturn Split the load between the front rack and rear rack with 1 3 in the front and 2 3 in the back Do not exceed load capacities See...

Page 35: ...an 15 Unbraked Trailer Towing Capacity is 1786 lbs 810 kg based on EU Directive 76 432 EC Using an improper hitch or exceeding the maximum tongue weight capacity can result in serious damage to the ve...

Page 36: ...he AWD switch is on Activating the override switch with the throttle open and while operating in reverse can cause loss of control Do not activate the override switch while the throttle is open Moment...

Page 37: ...G LIGHTS ON position The parking lights and taillights are on in this position See page 54 for starting procedures Engine Stop Switch The engine will not start or run when the switch is in the OFF pos...

Page 38: ...will also flash Return the toggle to the center posi tion to end the signal Horn Switch Press the horn switch to sound the horn Hazard Warning Switch Push the hazard warning switch to cause all turn...

Page 39: ...ate a vehicle with sticking or improperly operating throttle controls Contact your dealer for repair if throttle problems arise Press the throttle lever to increase engine speed and vehicle movement R...

Page 40: ...rates both front and rear brakes Squeeze the brake lever toward the handlebar to apply the all wheel brakes If the rear wheels begin to skid or slide while using the brake reduce lever pressure Aggres...

Page 41: ...handlebar 3 Push the parking brake lock forward to engage the lock 4 Release the brake lever 5 To release the parking brake lock squeeze and release the brake lever Operating the vehicle while the pa...

Page 42: ...place The lock must be replaced if the keys are lost 1 Turn the handlebars to the full left position 2 Insert the steering lock key and turn it clockwise 3 Remove the key 4 Reverse the procedure to u...

Page 43: ...100 hours of operation or annually Do not attempt to clean the fuel filter Fuel Tank Cap This vehicle is equipped with a digital fuel gauge that will indi cate a low fuel condition Refuel when the gau...

Page 44: ...move the lever to the desired gear Shifting gears with the engine speed above idle or while the vehicle is moving can cause transmission damage Whenever the vehicle is left unattended always place th...

Page 45: ...le tightly 2 Pull slightly until the starter mechanism engages 3 Pull the rope abruptly to start the engine Extending the recoil starter rope until it stops can cause damage to the recoil assembly Do...

Page 46: ...e spinning release the throttle before switching to AWD Tip The override switch allows activation of AWD in reverse if the AWD switch is on See page 34 Switching to AWD while the rear wheels are spinn...

Page 47: ...nction that limits the vehicle s speed to approximately 11 14 km h Refer to page 34 for addi tional information High water pressure may damage vehicle components Wash the vehicle by hand or with a gar...

Page 48: ...Gear L Low Gear N Neutral R Reverse Gear P Park 2 AWD Indicator This indicator illuminates when the AWD switch is in the AWD position 3 Engine Hour Display Indicator 4 Service Interval Diagnostic Mod...

Page 49: ...traveled by the vehicle on each trip if it s reset before each trip To reset the trip meter select the trip meter mode Press and hold the mode button override button until the total changes to 0 NOTE...

Page 50: ...nd on Any move ment of the tires will also cause the gauge to exit the diagnostic mode To enter the diagnostics mode 1 Turn the key switch off and wait 10 seconds 2 Lock the parking brake 3 Place the...

Page 51: ...your dealer for all major repairs Gear Circuit Diagnostic Screen This screen displays the resistance value in ohms being read at the gear switch input of the gauge This screen is for informational pur...

Page 52: ...button 4 Press and release the mode button once to advance the setting by one hour Press and hold the mode button to advance the hours quickly 5 If you scroll past the intended number press and hold...

Page 53: ...le it s on the vehicle Static electricity between the rack and container could cause a spark Do not smoke or allow open flames or sparks in or near the area where refu eling is performed or where gaso...

Page 54: ...k in 1 Fill the fuel tank with the recommended fuel See page 41 2 Check the oil level Add oil if necessary 3 Select an open area that allows room to familiarize yourself with vehicle operation and han...

Page 55: ...nuts bolts fasteners Inspect ensure tightness Fuel and oil Ensure proper levels 41 70 Throttle Ensure proper operation 37 89 Indicator lights switches Ensure proper operation 34 Engine stop switch En...

Page 56: ...tarting a warm engine Excessive use of the choke can cause the spark plug to become wet fouled 5 If the engine is cold pull the choke knob out until it stops If the knob doesn t stay where positioned...

Page 57: ...aid in starting Release the throttle lever immediately after the engine starts If the engine does not start and all conditions are favorable change the spark plug and try again 11 If the engine slows...

Page 58: ...ency situation Never connect DC powered winches to AC current Motor damage or fatal shock may occur Stand clear of the cable and load during winching Keep helpers and spectators at a safe distance If...

Page 59: ...ferent amount of load causing the strands under the greatest tension to break This reduces the load capacity of the entire cable 4 Before re spooling remove all load from the cable Hold the han dlebar...

Page 60: ...the switch and wiring for cracks pinched spots frayed wire or loose connections A damaged shortened lead could cause the winch to operate as soon as it is plugged in Never touch the cable or hook whil...

Page 61: ...ch the hook back onto the cable Doing so can cause the cable to break Always use a handsaver Do not hold the hook with your hand This is important not only when reeling cable in but also when removing...

Page 62: ...ing 6 Extended winching will discharge your battery If the low battery warning light comes on stop winching Make sure the transmission is in neutral or park then rev the motor for a few minutes until...

Page 63: ...y reduce the pulling power of your winch If the winch is still not capable of pulling the load use a snatch block 14 Never pull with less than five wraps of cable on the spool 15 Inspect the condition...

Page 64: ...omplies with the EMC requirements of European directives 97 24 EC and 2004 108 EC Non ionizing Radiation This vehicle emits some electromagnetic energy People with active or non active implantable med...

Page 65: ...rtant for proper vehicle operation If you re not familiar with safe service and adjustment procedures have a qualified dealer perform these operations Severe Use Definition Frequent immersion in mud w...

Page 66: ...rious injury or death Always have an authorized POLARIS dealer perform these services Maintenance Chart Key Perform these operations more often for vehicles subjected to severe use E Emission related...

Page 67: ...vel Pre Ride Winch Pre Ride See pages 57 58 E Air filter pre filter Daily Inspect clean often replace as needed Air box sediment tube Daily Drain deposits when visible Coolant Daily Check level daily...

Page 68: ...if necessary E Carburetor air intake ducts flange 50 6 M 800 Inspect duct for proper seal ing air leaks Drive belt 50 6 M 800 Inspect adjust replace as needed Cooling system 50 6 M 800 Inspect coolant...

Page 69: ...0 Inspect replace as needed Wiring 100 12 M 1600 Inspect for wear routing security apply dielectric grease to connectors subjected to water mud etc Clutches drive and driven 100 12 M 1600 Inspect clea...

Page 70: ...ication interval Item Lube Method Engine Oil PS 4 PLUS Performance Synthetic 2W 50 See page 69 Brake Fluid DOT 4 Only See page 82 Transmission Oil AGL PLUS Transmission Fluid See page 75 Front Demand...

Page 71: ...ARIS oil is not used Always use 2W 50 oil Follow the manufacturer s recommendations for ambient temperature operation See page 122 for the part numbers of POLARIS products Mixing brands or using a non...

Page 72: ...ngine Allow it to idle for 30 seconds 4 Stop the engine 5 Remove the dipstick Wipe it dry with a clean cloth 6 Reinstall the dipstick completely 7 Remove the dipstick and check the oil level Add oil a...

Page 73: ...ransmission in PARK 3 Start the engine Allow it to idle for two minutes 4 Stop the engine 5 Clean the area around the drain plug 6 Place a drain pan under the oil tank 7 Remove the drain plug 8 Drain...

Page 74: ...4 N m 13 Reattach the oil line 14 Place towels under the oil filter Using an oil filter wrench turn the filter counter clockwise to remove it 15 Clean the filter sealing area on the crankcase 16 Lubri...

Page 75: ...itially 22 Reinstall the dipstick 23 Place the transmission in PARK 24 Prime the oil pump using the procedure on page 74 25 Stop the engine Check for oil leaks 26 Check the oil level Add oil as needed...

Page 76: ...nected 1 Clamp the vent line 5 cm from the oil tank between the end of the oil tank vent fitting and the vent line s pressure relief slit 2 Start the engine Allow it to idle for 10 20 seconds 3 Remove...

Page 77: ...ion the vehicle on a level surface 2 Place the transmission in PARK 3 Remove the fill plug 4 Check the oil level Maintain the level at the bottom of the fill hole threads 5 Add the recommended oil as...

Page 78: ...in PARK 3 Remove the fill plug 4 Remove the drain plug 5 Drain the oil into a drain pan 6 Clean the drain plug 7 Reinstall the drain plug Torque to specification See page 75 8 Add the recommended oil...

Page 79: ...the fluid level at the bottom of the fill hole threads Fluid Level 1 Position the vehicle on a level surface 2 Place the transmission in PARK 3 Remove the fill plug 4 Add the recommended demand drive...

Page 80: ...e transmission in PARK 3 Remove the fill plug 4 Remove the drain plug Drain the fluid into a drain pan 5 Clean the drain plug 6 Reinstall the drain plug Torque to specification See page 77 7 Add the r...

Page 81: ...et and temperatures below 40 degrees F 4 degrees C Continuous operation of the engine without proper jetting when required can cause poor performance overheating or PVT or engine damage See your POLAR...

Page 82: ...ee page 122 for the part numbers of POLARIS products Always follow the manufacturer s mixing recommendations for the freeze protection required in your area Recovery Bottle Coolant Some coolant level...

Page 83: ...he outer edges of the panel inward to remove the panel 3 Remove the radiator pressure cap 4 If coolant is not visible slowly add coolant through the radiator filler neck 5 Reinstall the pressure cap U...

Page 84: ...s of POLARIS products An over full master cylinder may cause brake drag or brake lock up which could result in serious injury or death Maintain brake fluid at the recommended level Do not overfill Und...

Page 85: ...erfill 1 Position the vehicle on a level surface Make sure the handlebars are straight 2 View the fluid level through the indicator win dow eye on the top of the master cylinder Tip The eye will appea...

Page 86: ...Foot Brake 1 Position the vehicle on a level surface 2 Remove the seat 3 View the fluid level in the master cylinder 4 Maintain the fluid level between the minimum and maximum marks Do not overfill F...

Page 87: ...ake systems in good operat ing condition Check more often if brakes are used heavily under normal operation 1 Always keep brake fluid at an adequate level See page 82 2 Check the brake systems regular...

Page 88: ...n two stands as shown in the illustration Position the stands so that the string is flush with the side of the rear tire If available you may use a long straight edge instead of string 4 Measure the d...

Page 89: ...g in loss of control Follow the adjustment procedures exactly or see your POLARIS dealer for service 1 Remove the upper headlight pod 2 Loosen the four handlebar bolts 3 Adjust the handlebar to the de...

Page 90: ...the panel outward to disengage the side panel from the grommet 4 Pull the panel downward and rearward to remove it Footwell Removal 1 Remove the four screws on the bottom of the footwell 2 Use a flat...

Page 91: ...en the adjuster lock nut 4 Rotate the boot to turn the adjuster until 1 6 3 2 mm of freeplay is achieved at the thumb lever Move the throt tle lever back and forth while adjusting 5 Tighten the lock n...

Page 92: ...he tread depth measures 3 mm or less Refer to the specifications section beginning on page 120 for recom mended tire type size and pressure Tire Tread Depth Always replace tires when tread depth is wo...

Page 93: ...ce 2 Place the transmission in PARK 3 Loosen the wheel nuts slightly 4 Place a suitable stand under the footrest frame to raise the wheel slightly off the ground 5 Remove the wheel nuts 6 Remove the w...

Page 94: ...hicle on a level surface 2 Place the transmission in PARK 3 Remove the seat 4 Release the air box cover clips 5 Remove the air box cover 6 Loosen the hose clamp 7 Remove the filter 8 Remove the pre fi...

Page 95: ...ect the filter for debris Blow gently through the filter in the direction of the arrow to check for clogging Replace a damaged or clogged filter 4 Check the hoses for cracks deterioration abrasion or...

Page 96: ...n PARK 3 Measure the distance from the floor to the center of the headlight and make a mark on the wall at the same height Include rider weight on the seat when measuring 4 Start the engine Turn the h...

Page 97: ...e lamp 1 Place the transmission in PARK 2 Reach under the front bumper area to locate the lighting connectors 3 Parking Light Lamp Disconnect the harness connector Turn the socket counter clockwise 1...

Page 98: ...all components in reverse order Front Turn Signal Replacement If a front turn signal light becomes inoperable the lamps cannot be replaced Replace the entire signal lamp assembly Rear Turn Signal Lam...

Page 99: ...ement Locate and correct any short circuits that may have caused the blown fuse then replace the fuse Spare fuses are provided in a compartment 1 Open the front box cover 2 Remove the suspect fuse fro...

Page 100: ...rown There will be few combustion deposits The electrodes are not burned or eroded This indicates the proper type and heat range for the engine and the service The tip should not be white A white insu...

Page 101: ...spark plug wrench to remove the spark plug Turn the plug counter clockwise to remove it 4 Inspect the electrodes for wear and carbon buildup Replace worn or fouled plugs Verify that the gap is at spe...

Page 102: ...fully submerged major engine damage can result if the machine is not thoroughly inspected Take the vehicle to your dealer before starting the engine 1 Move the vehicle out of the water 2 Turn the fue...

Page 103: ...8 8 Tighten the carburetor drain screw 9 Turn the fuel valve on 10 Attempt to start the engine If necessary repeat the drying procedure 11 Have the vehicle serviced by your dealer promptly whether you...

Page 104: ...s Exhaust contains poisonous carbon monoxide gas Never go under the vehicle while it s inclined Remove any combustible materials from the area Wear eye protection and leather work gloves Do not stand...

Page 105: ...et while repeat ing step 5 8 If particles are still suspected to be in the muffler elevate the rear of the vehicle 30 cm higher than the front Block the wheels 9 Place the transmission in PARK Repeat...

Page 106: ...utch components Extensive engineering and testing has been conducted to ensure the safety of this product However as the owner you have the following responsibilities to make sure this system remains...

Page 107: ...varying throttle for 10 15 seconds to expel the moisture and air dry the belt and clutches Do not hold the throttle wide open for more than 10 seconds 6 Allow the engine RPM to settle to idle speed t...

Page 108: ...letely dry before reinstalling the drain plug 1 Place the transmission in PARK 2 Stop the engine 3 Remove the drain screw on the bottom of the recoil housing 4 Allow the housing to drain com pletely 5...

Page 109: ...uce explosive gases Keep sparks flame cigarettes etc away Ventilate when charging or using in an enclosed space Always shield eyes when working near batteries KEEP OUT OF REACH OF CHILDREN Your vehicl...

Page 110: ...move the battery vent tube 6 Disconnect the black negative battery cable first 7 Disconnect the red positive battery cable last 8 Lift the battery out of the vehicle Be careful not to tip a conven tio...

Page 111: ...umulate in an improperly installed vent tube and cause an explosion resulting in serious injury or death Always ensure that the vent tube is free of obstructions and is securely installed as recommend...

Page 112: ...sing a POLARIS Battery Tender charger or by charging about once a month to make up for normal self discharge Battery Tender can be left connected during the storage period and will automatically charg...

Page 113: ...front of the vehicle Battery Charging Sealed Battery The following battery charging instructions apply only to the installa tion of a sealed battery Read all instructions before proceeding with the i...

Page 114: ...may explode causing severe injury or death Always watch charging times carefully Stop charging if the battery becomes very warm to the touch Allow it to cool before resuming charging Always verify bat...

Page 115: ...lastic surfaces Do not allow these types of products to contact the vehicle 1 Use a professional type washing cloth cleaning the upper body first and the lower parts last 2 Rinse with clean water freq...

Page 116: ...S dealer to purchase a replacement Replacement safety labels are provided by POLARIS at no charge Grease all zerk fittings immediately after washing Allow the engine to run for a while to evaporate an...

Page 117: ...Never use abrasive cleaners on plated or painted surfaces 2 Rinse well with clear water Soap detergents salt dirt mud and other elements can cause corrosion 3 Polish the clean chrome wheels periodical...

Page 118: ...tions on the container for the recom mended amount Carbon Clean removes water from fuel systems stabilizes fuel and removes carbon deposits from pistons rings valves and exhaust systems 3 Allow the en...

Page 119: ...e page 116 2 Remove the spark plug Pour 30 45 ml of engine oil into the plug holes 3 Reinstall the spark plugs Torque to specification 4 Apply dielectric grease to the inside of each spark plug cap Re...

Page 120: ...off the ground 2 Be sure the storage area is well ventilated 3 Cover the vehicle with a genuine POLARIS cover Do not use plas tic or coated materials They do not allow enough ventilation to pre vent...

Page 121: ...ent loss during transporting 5 Always tie the frame of the POLARIS vehicle to the transporting unit securely with suitable straps or rope Do not attach tie straps to the front A arm bolt pockets Towin...

Page 122: ...eelbase 50 75 in 128 9 cm Ground Clearance 11 in 28 cm Minimum Turning Radius 65 in 165 cm unloaded Engine EH500PLE Low Torque Capacity 4 Stroke Displacement 498 cc Engine Power 27 kW Bore x Stroke 92...

Page 123: ...all wheels Parking Brake Hydraulic lock on all wheels Mechanical Lock in Park Hitch Rear mount for attachment of coupling devices Winch Front permanent Installed winch with 2500 Lbs 1 125 Kg Capacity...

Page 124: ...emium Demand Drive Hub Fluid 237 ml 2872277 Premium Demand Drive Hub Fluid 9 5 l Coolant 2871323 60 40 Coolant 3 8 l 2871534 60 40 Coolant 95 l Grease Specialized Lubricants 2871312 Grease Gun Kit Pre...

Page 125: ...e low range only Utility use plowing Use low range only Stuck in mud or snow Shift the transmission to low range Carefully use fast aggressive throttle application to engage clutch WARNING Excessive t...

Page 126: ...ned off Turn the fuel valve on Fouled or defective spark plug s Inspect plugs and replace if necessary No spark to spark plug Inspect plugs verify stop switch is on Water or fuel in crankcase Immediat...

Page 127: ...place with recommended fuel Clogged air filter Inspect and clean or replace Reverse speed limiter malfunction See your dealer Electronic throttle control malfunction See your dealer Other mechanical f...

Page 128: ...Set gap to specs or replace plug Loose ignition connections Check all connections and tighten Low battery voltage Recharge the battery to 12 8 VDC Incorrect fuel Replace with fresh recommended fuel C...

Page 129: ...time of sale the Warranty Registration Form must be completed by your dealer and submitted to POLARIS within ten days Upon receipt of this registration POLARIS will record the registration for warrant...

Page 130: ...orized parts In addition this warranty does not cover physical damage to paint or finish stress cracks tearing or puncturing of upholstery material corrosion or defects in parts components or the vehi...

Page 131: ...ignment tension adjustment or altitude compensation failure due to snow water dirt or other foreign substance ingestion contamination improper maintenance modified components use of aftermarket compon...

Page 132: ...RRANTIES 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 DIS...

Page 133: ...ection 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 KILOMETERS OR HOURS TEC...

Page 134: ...132 MAINTENANCE LOG DATE KILOMETERS OR HOURS TECHNICIAN SERVICE PERFORMED COMMENTS...

Page 135: ...133 MAINTENANCE LOG DATE KILOMETERS OR HOURS TECHNICIAN SERVICE PERFORMED COMMENTS...

Page 136: ...81 Cooling System 80 81 Corrosion Removal Chrome 115 D Demand Drive Fluid 77 78 Drive Belt Wear Burn 123 Drivetrain Break In 52 Driving Downhill 25 Driving in Reverse 31 Driving on a Sidehill 24 Drivi...

Page 137: ...justment 94 Headlight Lamp 95 Momentary High Beam Switch 34 Position Light Lamp 95 Rear Turn Signal 96 Taillight 96 Low Range Use 105 Lubrication Guide 68 M Maintenance Chart 63 67 Mirrors 37 Mode Swi...

Page 138: ...Momentary High Beam Switch 34 Turn Signal Switch 36 Winch Switch 34 T Taillight 96 Throttle Cable Freeplay 89 Throttle Lever 37 Tire Tread Depth 90 Tires 90 91 Front Wheel Hub Tightening 90 Tread Dep...