Polaris Sportsman 450 2022 Owner's Manual
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Polaris Sportsman 450 2022 Owner's Manual

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2022
For Maintenance and Safety
OWNER'S
MANUAL
Sportsman 450
Sportsman 570
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.
WARNING

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  • Page 1 2022 For Maintenance and Safety OWNER’S MANUAL Sportsman 450 Sportsman 570 WARNING 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.
  • Page 2 For more information go to www.P65Warnings.ca.gov/passenger-vehicle. For videos and more information about a safe riding experience with your Polaris vehicle, scan this QR code with your smartphone.
  • Page 3 2022 Owner’s Manual Sportsman 450 H.O. Sportsman 450 H.O. EPS Sportsman 450 H.O. Utility Sportsman 570 Sportsman 570 EPS Sportsman 570 EPS Utility Sportsman 570 Premium Sportsman 570 Hunt Edition Sportsman 570 Trail Sportsman 570 Utility HD Sportsman 570 Ultimate Trail...
  • Page 4 Rubber (USA) Inc. DBA Duro Tire & Wheel Corp. AUTOLITE® is a registered trademark of BMO HARRIS BANK N.A. Unless noted, trademarks are the property of Polaris Industries Inc. Copyright 2021 Polaris Industries Inc. All information contained within this publication is based on the latest product information at the time of publication.
  • Page 5 WELCOME Thank you for purchasing a POLARIS vehicle, and welcome to our world-wide family of POLARIS enthusiasts. Be sure to visit us online at www.polaris.com for the latest news, new product introductions, upcoming events, career opportunities and more. Here at POLARIS we proudly produce an exciting line of utility and recreational products.
  • Page 6 WELCOME...
  • Page 7 Specifications ....171 POLARIS Products ....187 Troubleshooting ....189 Warranty .
  • Page 9 WARNING Failure to heed the warnings and safety precautions contained in this manual can result in severe injury or death. A POLARIS ATV is not a toy and can be hazardous to operate. This vehicle handles differently than other vehicles, such as motorcycles and cars.

  • Page 10: Safety Symbols And Signal Words

    INTRODUCTION SAFETY SYMBOLS AND SIGNAL WORDS The following signal words and symbols appear throughout this manual and on your vehicle. Your safety is involved when these words and symbols are used. Become familiar with their meanings before reading the manual. DANGER DANGER indicates a hazardous situation which, if not avoided, WILL result in death or serious injury.

  • Page 11: Vehicle Identification Numbers

    Remove the spare key and store it in a safe place. An ignition key can be duplicated only by ordering a POLARIS key blank (using your key number) and mating it with one of your existing keys. The ignition switch must be replaced if all keys are lost.

  • Page 12: Radio Compliance Statements

    Semiconductor® 9200 Series Display RC-7W Polaris Industries Inc. This device complies with part 15 of the FCC Rules. Operation is subject to the following two conditions: (1) This device may not cause harmful interference, and (2) this device must accept any interference received, including interference that may cause undesired operation.
  • Page 13 For applications that use vehicle-to-vehicle (V2V) communication, radio transmitter IC 5966A-RC7W has been approved by Innovation, Science and Economic Development Canada (ISED) to operate with Polaris antenna (part number 4080356) with gain of 3 dBi. Any antenna that has a gain greater than...

  • Page 15: Safety Training

    You should review this information on a regular basis. If you purchased a used POLARIS ATV in the United States, you can enroll in the ATV RiderCourse for a fee. Call ATV Enrollment Express at (800) 887- 2887 or visit www.atvsafety.org.

  • Page 16: Eye Protection

    HELMET Wearing a helmet can prevent a severe head injury. Whenever riding this POLARIS vehicle, always wear a helmet that meets or exceeds established safety standards. Clasp the buckle and pull each strap tight to ensure the helmet is properly secured to the head.

  • Page 17: Safety Warnings

    SAFETY SAFETY WARNINGS WARNING Failure to operate this vehicle properly can result in a collision, loss of control, accident or rollover, which may result in serious injury or death. Heed all safety warnings outlined in this section of the owner’s manual and in the safety DVD provided with your vehicle.

  • Page 18: Using Alcohol Or Drugs

    SAFETY USING ALCOHOL OR DRUGS Never consume alcohol or drugs before or while operating this vehicle. Operating this vehicle after consuming alcohol or drugs could adversely affect operator judgment, reaction time, balance and perception. FAILURE TO INSPECT BEFORE OPERATING WARNING Failure to inspect and verify that the vehicle is in safe operating condition before operating increases the risk of an accident.

  • Page 19: Exposure To Exhaust

    SAFETY EXPOSURE TO EXHAUST CAUTION Engine exhaust fumes are poisonous and can cause loss of consciousness or death in a short time. Never start the engine or let it run in an enclosed area. Operate this vehicle only outdoors or in well-ventilated areas. PROTECTIVE APPAREL Riding in this vehicle without wearing an approved helmet and protective eye wear...

  • Page 20: Operating At Excessive Speeds

    SAFETY OPERATING AT EXCESSIVE SPEEDS Operating this vehicle at excessive speeds increases the operator's risk of losing control. Always operate at a speed that's appropriate for the terrain, the visibility and operating conditions and your skills and experience. PHYSICAL CONTROL OF THE VEHICLE Removing even one hand or foot can reduce ability to control the vehicle or could cause loss of balance and ejection from the ATV.

  • Page 21: Jumps And Stunts

    SAFETY JUMPS AND STUNTS Exhibition driving increases the risk of an accident or rollover. DO NOT do power slides, “donuts”, jumps or other driving stunts. Avoid exhibition driving. IMPROPER HILL CLIMBING Improper hill climbing could cause loss of control or rollover. Use extreme caution when operating on hills.

  • Page 22: Stalling While Climbing A Hill

    SAFETY STALLING WHILE CLIMBING A HILL Stalling, rolling backwards or improperly dismounting while climbing a hill could cause a rollover. • Always maintain a steady speed when climbing a hill. • Always engage ADC mode (if equipped) before ascending or descending a hill. If ADC mode is not equipped, apply AWD mode before ascending or descending a hill.

  • Page 23: Operating On Steep Hills

    SAFETY OPERATING ON STEEP HILLS Operating on excessively steep hills could cause an overturn. Never operate on hills too steep for the ATV or for your abilities. Never operate this ATV on hills steeper than 25 degrees. OPERATING ON SLIPPERY TERRAIN Failure to use extra caution when operating on excessively rough, slippery or loose terrain could cause loss of traction, loss of...

  • Page 24: Improper Tire Maintenance

    SAFETY 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 owner's manual and on safety labels.

  • Page 25: Skidding Or Sliding

    SAFETY SKIDDING OR SLIDING Failure to use extra caution when operating on excessively rough, slippery or loose terrain could cause loss of traction, loss of control, accident or rollover. Do not operate on excessively slippery surfaces. Always slow down and use additional caution when operating on slippery surfaces.

  • Page 26: Improper Cargo Loading

    SAFETY IMPROPER CARGO LOADING Overloading the vehicle or carrying cargo improperly may cause changes in stability and handling, which could cause loss of control or an accident. • Always follow the instructions in this owner’s manual for carrying cargo. • Never exceed the stated load capacity for this vehicle. •...

  • Page 27: Hot Exhaust Systems

    EQUIPMENT MODIFICATIONS Your POLARIS vehicle is designed to provide safe operation when used as directed. Modifications to your vehicle may negatively impact vehicle stability. Failure of critical machine components may result from operation with any modifications, especially those that increase speed or power.
  • Page 28 The POLARIS limited warranty on your POLARIS vehicle will be terminated if any non-POLARIS approved equipment and/or modifications have been added to the vehicle that increase speed or power.

  • Page 29: Safety Labels And Locations

    If an informational or graphic label becomes illegible or comes off, contact your POLARIS dealer to purchase a replacement. Replacement safety labels are provided by POLARIS at no charge. The part number is printed on the label. OVERVIEW General Warning...

  • Page 30: General Warning

    SAFETY GENERAL WARNING WARNING Improper use can result in SEVERE INJURY or DEATH ALWAYS USE AN APPROVED HELMET AND PROTECTIVE GEAR NEVER USE ON PUBLIC ROADS NEVER CARRY PASSENGERS NEVER USE WITH DRUGS OR ALCOHOL NEVER operate: • without proper training or instruction •...

  • Page 31: Clutch Cover Warning

    SAFETY REVERSE OVERRIDE / AWD WARNING WARNING Improper use of override button can lead to loss of control resulting in severe injury or death. Do not activate override while throttle is engaged. Always apply throttle gradually, while in reverse. CAUTION Do not push switch to engage 4X4 (AWD) if the rear wheels are spinning.

  • Page 32: Discretionary Warning

    SAFETY DISCRETIONARY WARNING WARNING • Never operate this ATV on HILLS steeper than 25 degrees. To prevent overturn on hilly terrain, use throttle and brakes gradually, and shift weight uphill. • REVERSE operation can be dangerous even at low speeds. Steering becomes difficult.

  • Page 33: Features And Controls

    FEATURES AND CONTROLS FEATURES AND CONTROLS OVERVIEW NOTICE The image below is shown for reference only. Your model may vary slightly. Ignition Switch Auxiliary Switch (if equipped) Engine Stop Switch Thumb Warmer Switch (if equipped) Mode/Reverse Override Switch Hand Warmer Switch (if equipped) Headlight Switch Brake Lever Throttle Lever...

  • Page 34: Ignition Switch

    FEATURES AND CONTROLS IGNITION SWITCH Use the ignition switch to start the engine. The key can be removed from the switch when it is in the OFF position. SWITCH FUNCTION POSITION Turn the key to the OFF position to stop the engine. Electrical circuits are off. Turn the key the RUN position to activate electrical components.

  • Page 35: Left-Hand Control

    FEATURES AND CONTROLS LEFT-HAND CONTROL ENGINE STOP SWITCH Move the stop switch either left or right to the OFF position to stop the engine quickly. Move the stop switch to the RUN position before attempting to start the engine. The engine will not start or run when the switch is off.

  • Page 36: Headlight Switch

    Operating an ATV with sticking or improperly operating throttle controls could cause an accident. Never start or operate an ATV that has a sticking or improperly operating throttle. Immediately contact your POLARIS dealer or other qualified person for service if throttle problems arise.
  • Page 37 FEATURES AND CONTROLS DRIVELINE SWITCH (IF EQUIPPED) The Driveline switch controls the All Wheel Drive (AWD) system. Use this switch to engage ADC 4x4, 4x4 (AWD), 2X4, or Turf Mode (if equipped). The vehicle automatically engages AWD when operating in reverse if the drive mode is set to AWD.

  • Page 38: Performance Mode

    FEATURES AND CONTROLS DRIVE MODE SWITCH (IF EQUIPPED) The Drive Mode Switch has three positions: • Performance (PERF) • Standard (STND) • Work (WORK) Always use low gear for any of the following conditions regardless of the selected throttle control setting. •...

  • Page 39: All Wheel Drive System

    FEATURES AND CONTROLS ALL WHEEL DRIVE SYSTEM NOTICE Switching to AWD while the rear wheels are spinning may cause severe drive shaft and gearcase damage. Always switch to AWD while the rear wheels have traction or are at rest. The All Wheel Drive (AWD) system is controlled by the Driveline switch. Engage AWD before getting into conditions where front wheel drive may be needed.
  • Page 40 FEATURES AND CONTROLS AWD (4X4) MODE When the switch is on AWD, the ATV is four-wheel drive, and the AWD indicator icon in the instrument cluster display will be visible. When in AWD, the demand drive unit will automatically engage any time the rear wheels lose traction. When the rear wheels regain traction, the demand drive unit will automatically disengage.

  • Page 41: Engaging Awd

    FEATURES AND CONTROLS ADC 4X4 MODE (IF EQUIPPED) When the switch is on ADC 4X4, the ADC system allows engine braking to all four wheels when the vehicle descends a hill or incline. Always move the 4X4 switch to ADC 4X4 before ascending or descending a hill.

  • Page 42: Awd Mode

    FEATURES AND CONTROLS ALL WHEEL DRIVE SYSTEM Available on California, HD Utility LE, and Ultimate Trail Models The All Wheel Drive system (AWD) is controlled by the AWD momentary switch Engage AWD before getting into conditions where front wheel drive may be needed.

  • Page 43: Adc Awd Mode (If Equipped)

    FEATURES AND CONTROLS ADC AWD MODE (IF EQUIPPED) To engage ADC AWD Mode, push the momentary switch to the right twice. When the switch is on ADC AWD, the ADC system allows engine braking to all four wheels when the vehicle descends a hill or incline. Always move the AWD switch to ADC AWD before ascending or descending a hill.

  • Page 44: Brake System

    Any sponginess would indicate a possible fluid leak or low master cylinder fluid level, which must be corrected before riding. Contact your POLARIS dealer or other qualified service facility for proper diagnosis and repairs. MASTER CYLINDER/BRAKE FLUID WARNING An over-full master cylinder may cause brake drag or brake lock-up, which could result in an accident.

  • Page 45: Parking Brake

    FEATURES AND CONTROLS 4. If the fluid level is low, remove the cover screws and add fluid to the fill line. Do not overfill. Use DOT 4 brake fluid only. 5. Reinstall the cover. Torque screws to 7 in-lbs (1 N·m). WARNING Never store or use a partial bottle of brake fluid.

  • Page 46: Auxiliary Foot Brake

    FEATURES AND CONTROLS AUXILIARY FOOT BRAKE WARNING Never back down a hill. Applying the auxiliary brake when backing down a hill may cause rear tipover, which could result in serious injury or death. Use caution when applying the auxiliary brake. Do not aggressively apply the auxiliary brake when going forward.

  • Page 47: Automatic Transmission Gear Selector

    FEATURES AND CONTROLS AUTOMATIC TRANSMISSION GEAR SELECTOR The transmission gear selector is located on the right side of the vehicle. H: High Gear L: Low Gear N: Neutral R: Reverse P: Park To shift gears, brake to a complete stop. When the engine is idling, move the lever to the desired gear.

  • Page 48: Instrument Cluster

    FEATURES AND CONTROLS INSTRUMENT CLUSTER NOTICE Features vary by model. Your ATV is equipped with one of three available gauge variants, (1) a standard gauge (no Bluetooth® functionality), (2) a Bluetooth®-equipped gauge, and (3) a no-button gauge. If your gauge is equipped with Bluetooth®, the Bluetooth® icon will briefly display in the upper right corner of the gauge at start-up.
  • Page 49 All segments including the fuel icon will flash. Refuel immediately. A flashing wrench symbol alerts the operator that the Service preset service interval has been reached. Your POLARIS Indicator dealer can provide scheduled maintenance. See page 66 for more information.

  • Page 50: Indicator Lamps

    EPS Warning (if This indicator illuminates when a fault equipped) has occurred in the EPS system. Your authorized POLARIS dealer can assist. EPS operation is possible with key on/ engine off for up to 5 minutes. Engine Hot This lamp illuminates to indicate an overheated engine.
  • Page 51 FEATURES AND CONTROLS INDICATOR ICON FUNCTION Chassis Fault If applicable. Performance On models equipped with a low speed Limited limiter, indicator light will remain on when low speed limiter is active. Lamp illuminates when Geofencing or max speed is enabled. Lamp remains off when Geofencing and max speed settings are disabled.
  • Page 52 FEATURES AND CONTROLS NO BUTTON GAUGE Some Sportsman models are equipped with a no-button gauge. This gauge style does not come equipped with a clock feature. Other available features may vary. To toggle through available features, press Reverse Override / Mode Button from the left hand controls.

  • Page 53: Display Area

    FEATURES AND CONTROLS DISPLAY AREA 1 Pressing the MODE button will change the information displayed in Area 1 DISPLAY AREA 1 FUNCTION Speed The vehicle’s speed will be displayed in mph, or km/h. Engine The vehicle’s current engine temperature will be Temperature displayed.
  • Page 54 FEATURES AND CONTROLS DISPLAY AREA 2 Toggle the Up/Down buttons to change the information displayed in Area 2 DISPLAY AREA 2 FUNCTION Odometer The vehicle’s odometer reading will be displayed. Engine The vehicle Engine Temperature will be displayed. Temperature Trip 1 The vehicle Trip 1 mileage will be displayed.

  • Page 55: Options Menu

    FEATURES AND CONTROLS OPTIONS MENU From the options menu you can view diagnostic codes, access the advanced menu, set the clock, and much more. For a full list of available options see below. To enter the Options Menu, press and hold the MODE button.

  • Page 56: Diagnostic Code

    FEATURES AND CONTROLS DIAGNOSTIC CODE Diagnostic Code Screen will show available MIL that has come on during that ignition cycle. To access the Diagnostic Code Screen, do the following: 1. Press and hold the MODE button to enter the Options Menu.

  • Page 57: Advanced Menu

    FEATURES AND CONTROLS NOTICE When the gauge is displaying a fault code, the warning telltale (check engine or EPS) will blink to indicate which controller set the fault code. 3. To exit the Options Menu the user can select Exit Menu function from Options Menu, can hold Mode Button and exit out of Options Menu, or not press any button for 10 seconds, which will exit out of the Options Menu.
  • Page 58 FEATURES AND CONTROLS MAXIMUM SPEED (IF EQUIPPED) 1. Press and hold the MODE button to enter the Options Menu. NOTICE “OPTIONS” will display on the screen for 3 seconds before showing first menu item. 2. Select “ADVANCED MENU” by pressing the MODE Button. 3.
  • Page 59 FEATURES AND CONTROLS GEOFENCING (IF EQUIPPED) Before you can use the geofencing features, you must first download the Polaris Ride Command app from the APPLE APP STORE® or Google Play® and create an account. Enabling and disabling a geofence, as well...
  • Page 60 FEATURES AND CONTROLS INSIDE GEOFENCE SPEED 1. Press and hold the MODE button to enter the Options Menu. NOTICE “OPTIONS” will display on the screen for 3 seconds before showing first menu item. 2. Select “ADVANCED MENU” by pressing the MODE button. 3.
  • Page 61 FEATURES AND CONTROLS OUTSIDE GEOFENCE SPEED 1. Press and hold the MODE button to enter the Options Menu. NOTICE “OPTIONS” will display on the screen for 3 seconds before showing first menu item. 2. Select “ADVANCED MENU” by pressing the MODE button. 3.

  • Page 62: Change Pin

    FEATURES AND CONTROLS CHANGE PIN 1. Press and hold the MODE button to enter the Options Menu. NOTICE “OPTIONS” will display on the screen for 3 seconds before showing first menu item. 2. Select “ADVANCED MENU” by pressing the MODE button. 3.

  • Page 63: Unit Selection Distance

    FEATURES AND CONTROLS UNIT SELECTION DISTANCE 1. Press and hold the MODE button to enter the Options Menu. NOTICE “OPTIONS” will display on the screen for 3 seconds before showing first menu item. 2. Select “Units-Distance” from the Options Menu by pressing the MODE button.

  • Page 64: Unit Selection Temperature

    FEATURES AND CONTROLS UNIT SELECTION TEMPERATURE 1. Press and hold the MODE button to enter the Options Menu. NOTICE “OPTIONS” will display on the screen for 3 seconds before showing first menu item. 2. Select “Units - Temp” from the Options Menu by pressing the MODE button. Reference the image shown above: Press the MODE button.
  • Page 65 FEATURES AND CONTROLS CLOCK (IF EQUIPPED) 1. Press and hold the MODE button to enter the Options Menu. NOTICE “OPTIONS” will display on the screen for 3 seconds before showing first menu item. 2. Select “Clock” from the Options Menu by pressing the MODE button. Reference the image shown above: Press the MODE button.

  • Page 66: Back Light Color

    FEATURES AND CONTROLS BACK LIGHT COLOR 1. Press and hold the MODE button to enter the Options Menu. NOTICE “OPTIONS” will display on the screen for 3 seconds before showing first menu item. 2. Select “Backlight Color” from the Options Menu by pressing the MODE button.

  • Page 67: Back Light Level

    FEATURES AND CONTROLS BACK LIGHT LEVEL 1. Press and hold the MODE button to enter the Options Menu. NOTICE “OPTIONS” will display on the screen for 3 seconds before showing first menu item. 2. Select “Backlight Level” from the Options Menu by pressing the MODE button.

  • Page 68: Service Hours

    FEATURES AND CONTROLS SERVICE HOURS 1. Press and hold the MODE button to enter the Options Menu. NOTICE “OPTIONS” will display on the screen for 3 seconds before showing first menu item. 2. Select “Service Hours” from the Options Menu by pressing the MODE button. Reference the image shown above: Press the MODE button.

  • Page 69: Auxiliary Outlet

    FEATURES AND CONTROLS AUXILIARY OUTLET A 12-volt accessory outlet is located on the pod. Use the outlet to power an auxiliary light or other optional accessories or lights. FUEL CAP This vehicle is equipped with a digital fuel gauge that will indicate a low fuel condition.

  • Page 70: Electronic Power Steering (Eps)

    FEATURES AND CONTROLS ELECTRONIC POWER STEERING (EPS) Electronic power steering (EPS), if equipped, engages when the ignition key is turned to the ON position. EPS remains engaged whether the vehicle is moving or idle. See the Instrument Cluster section for EPS Warning Indicator information.
  • Page 71 Be aware of all applicable local laws that may affect the use of electronic devices while riding. For the latest information about your Ride Command display, including software, maps, and trails updates, please visit: https://ridecommand.polaris.com. For a video overview of the display, please visit: https://youtu.be/4-YgaDGQZuo.

  • Page 72: Before You Ride

    Some features are limited when vehicle is in motion. Before riding with your new display, do the following: • Download the Polaris RIDE COMMAND App from the Apple®/Google Play® store and create your personalized account. • Check your display to ensure you have the appropriate maps and trails visible for your area.

  • Page 73: Button Description

    Zooms in when using the map and Up Button scrolls up through lists of features. Opens and closes the Badge Panel. Polaris Button Zooms out when using the map and Down Button scrolls down through lists of features. Cycles all screens and backs user Back Button out of menus.

  • Page 74: Gauge Screen

    RIDE COMMAND GAUGE SCREEN The Gauge Screen displays upon start-up and will serve as your primary interface when operating the vehicle. The Gauge Screen is fully customizable and can be configured to display as much, or as little, vehicle information as you like. Options include vehicle speed, RPM, fuel level, engine temperature,...
  • Page 75 RIDE COMMAND 3. In the left side panel, choose a gauge layout from the three provided options. ICON DESCRIPTION Two circular widgets and up to three linear widgets. Up to five linear widgets. Four circular widgets. 4. Select the Data tab .
  • Page 76 RIDE COMMAND 5. Reorder the widgets by pressing and holding down on the widget and sliding the widget up or down into the desired position. 6. Click the green check mark or Done to close the configuration panel. GAUGE VIEW MODE Press to toggle between the two available gauge view modes, analog and digital.

  • Page 77: Icon Description

    RIDE COMMAND ICON BAR The Icon Bar is located across the top of the touchscreen and displays cell phone, headset, and wireless internet connectivity, fuel level, compass heading and local time. NOTICE The Icon Bar will not appear when the Badge Panel is open. ICON DESCRIPTION FUNCTION...
  • Page 78 All Settings Button ACCESSING THE BADGE PANEL There are two ways to open the Badge Panel, press the Badge Panel button (Polaris Logo) the top of the touchscreen or the Polaris Menu hard button on the right of the display.

  • Page 79: Controls Tab

    RIDE COMMAND APP TRAY The App Tray provides easy access to key features on the display screen. Tap on any of the listed icons to navigate to that display screen. For example, tap the Maps button to navigate to the Map Screen, or press the Music button to navigate to the Audio Screen.

  • Page 80: Usb Drive

    RIDE COMMAND ENGINE OVERHEAT INDICATOR If the engine goes over temperature, a red banner will appear at the top of your display stating: ENGINE OVERHEATING – STOP IMMEDIATELY. The appearance of this banner indicates continued operation of your ATV could result in serious engine damage.

  • Page 81: Error Messages

    2. Remove and reconnect the USB flash drive securely. 3. Ensure display files are not inside a folder on the flash drive. 4. Only Polaris display files should be on the flash drive while performing updates. Remove other files, if necessary.

  • Page 82: Software Updates

    USB HARDWARE SOFTWARE UPDATES For software update, POLARIS recommends using a SanDisk®, Kinston®, or similar USB flash drive with a minimum of 4GB in available memory, formatted using the FAT32 or exFAT file systems. For best results remove all files from the flash drive before starting the update process.

  • Page 83: Safe Operation Practices

    OPERATION OPERATION SAFE OPERATION PRACTICES WARNING Failure to operate the vehicle properly can result in a collision, loss of control, accident or rollover, which may result in serious injury or death. Read and understand all safety warnings outlined in the safety section of this owner’s manual.

  • Page 84: Trail Etiquette

    VEHICLE BREAK-IN PERIOD The break-in period for your new POLARIS vehicle is the first 25 hours of operation, or the time it takes to use the first two tanks full of gasoline. No single action on your part is as important as a proper break-in period.

  • Page 85: Engine And Drivetrain Break-In

    OPERATION ENGINE AND DRIVETRAIN BREAK-IN 1. Fill the fuel tank with gasoline. See the Fuel Tank section for details. Always exercise extreme caution whenever handling gasoline. 2. Check the oil level. See the Oil Check section for reference. Add the recommended oil as needed to maintain the oil level in the safe operating range.

  • Page 86: Pre-Ride Checklist

    OPERATION PRE-RIDE CHECKLIST Failure to inspect and verify that the ATV is in safe operating condition before operating increases the risk of an accident. Always inspect the ATV before each use to make sure it's in safe operating condition. ITEM REMARKS PAGE page 42...

  • Page 87: New Operator Driving Procedures

    OPERATION DRIVING PROCEDURES NEW OPERATOR DRIVING PROCEDURES 1. Wear protective riding gear. See the Safe Riding Gear section. 2. Perform the pre-ride inspection. 3. Place the transmission in PARK. 4. Lock the brake holding latch. 5. Mount the vehicle from the left side.

  • Page 88: Turning The Vehicle

    OPERATION TURNING THE VEHICLE Both rear wheels drive equally at all times. 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.

  • Page 89: Driving On Slippery Surfaces

    OPERATION DRIVING ON SLIPPERY SURFACES WARNING Skidding or sliding can cause loss of control or rollover (if tires regain traction unexpectedly). When operating on slippery surfaces such as ice or loose gravel, reduce speed and use extra caution to reduce the chance of skidding or sliding out of control.

  • Page 90: Driving Uphill

    OPERATION DRIVING UPHILL Braking and handling are greatly affected when operating in hilly terrain. Improper procedure could cause loss of control or overturn. Whenever traveling uphill, follow these precautions: 1. Always engage ADC before ascending or descending a hill. 2. Drive straight uphill. 3.

  • Page 91: Driving Downhill

    OPERATION DRIVING DOWNHILL When driving downhill, follow these precautions: 1. Always check the terrain carefully before descending a hill. 2. Always engage ADC mode before ascending or descending a hill. 3. Avoid steep hills. Maximum incline is 25° 4. Always descend a hill with the transmission in forward gear. Do not descend a hill with the transmission in neutral.

  • Page 92: Driving On A Sidehill (Sidehilling)

    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.

  • Page 93: Turning Around On A Hill (K-Turn)

    OPERATION TURNING AROUND ON A HILL (K-TURN) If the vehicle stalls while climbing a hill, never back it down the hill! Use the K- turn to turn around. 1. Stop and lock the parking brake while keeping body weight uphill. 2.

  • Page 94: Driving Through Water

    If the vehicle tips or overturns in water, or if the engine stops during or after operating in water, service is required before starting the engine. Your POLARIS dealer can provide this service. If it's impossible to bring the vehicle in before starting the engine, perform the service outlined in the Vehicle Immersion section of this manual, and take the vehicle in for service at the first opportunity.

  • Page 95: Driving Over Obstacles

    OPERATION DRIVING OVER OBSTACLES Follow these precautions when operating over obstacles: 1. Always check for obstacles before operating in a new area. 2. Look ahead and learn to read the terrain. Be constantly alert for hazards such as logs, rocks and low hanging branches. 3.

  • Page 96: Driving In Reverse

    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.

  • Page 97: Starting The Engine

    OPERATION STARTING THE ENGINE 1. Position the vehicle on a level surface outdoors or in a well- ventilated area. 2. Place the transmission in PARK. 3. Lock the parking brake. 4. Sit on the vehicle and move the engine stop switch to RUN. NOTICE Do not press the throttle while starting the engine.

  • Page 98: Parking The Vehicle

    OPERATION PARKING THE VEHICLE 1. Stop the vehicle on a level surface. When parking inside a garage or other structure, be sure that the structure is well ventilated and that the vehicle is not close to any source of flame or sparks, including any appliance with pilot lights.

  • Page 99: Hauling Cargo

    OPERATION HAULING CARGO CARGO WARNING WARNING 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: REDUCE SPEED AND ALLOW GREATER DISTANCES FOR BRAKING WHEN HAULING CARGO.

  • Page 100: Towing Loads

    ATV warranty. Never install a hitch longer than 4" (10 cm). Never install automotive accessories on your POLARIS ATV. Always install POLARIS-approved (or equivalent) accessories designed for ATV use.
  • Page 101 OPERATION TRAILERING YOUR VEHICLE Follow these procedures when transporting the vehicle. 1. Stop the engine. 2. Place the transmission in PARK. 3. Secure the fuel cap, oil cap, and seat. 4. Remove the key to prevent loss during transporting. 5. Use suitable straps or rope to secure the vehicle to the front tow hook rear tow bracket .

  • Page 103: Winch Guide

    WINCH GUIDE WINCH GUIDE WINCH SAFETY These safety warnings and instructions apply if your vehicle came equipped with a winch or if you choose to add an accessory winch to your vehicle. WARNING Improper winch use can result in SEVERE INJURY or DEATH. Always follow all winch instructions and warnings in this manual.
  • Page 104 WINCH GUIDE 12. If winching at an angle is unavoidable, follow these precautions: a. Look at the winch drum occasionally. Never let the winch cable “stack” or accumulate at one end of the winch drum. Too much winch cable at one end of the winch drum can damage the winch and the winch cable.

  • Page 105: Winch Operation

    WINCH GUIDE WINCH OPERATION Read the Winch Safety Precautions in the preceding pages before using your winch. Consider practicing the operation and use of your winch before you actually need to use it in the field. WARNING Improper winch use can result in SEVERE INJURY or DEATH. Always follow all winch instructions and warnings in this manual.
  • Page 106 Replace the winch cable at the first sign of damage to prevent SEVERE INJURY or DEATH in the event of failure. For your safety, always replace POLARIS winch parts (including the cable) with genuine POLARIS replacement parts available at your authorized POLARIS dealer, or other qualified dealer.
  • Page 107 WINCH GUIDE • If possible, keep the winch cable aligned with the centerline of the winching vehicle. This will help the spooling of the winch cable and reduce the load on the fairlead. • If freeing a stuck vehicle by attaching to a tree, use an item such as a tow strap to avoid damaging the tree during winch operation.
  • Page 108 WINCH GUIDE c. On a long pull, it may be necessary to stop winching so that the damper can be repositioned to the new mid-point of the winch cable. Always release the tension on the winch cable before repositioning the damper. d.
  • Page 109 WINCH GUIDE 13. Extensive winching will run down the battery on the winching vehicle. Let the winching vehicle’s engine run while operating the winch to prevent the battery from running low if winching for long periods. 14. The winch motor may become hot during winch use. If you winch for more than 45 seconds, or if the winch stalls during operation, stop winching and permit the winch to cool down for 10 minutes before using it again.

  • Page 110: Winch Cable Care

    Use of worn or damaged cable could lead to sudden failure and SEVERE INJURY. For your safety, always replace POLARIS winch parts (including the cable) with genuine POLARIS replacement parts available at your authorized POLARIS dealer, or other qualified person.

  • Page 111: Shock Loading

    WINCH GUIDE SHOCK LOADING WARNING Your winch cable is very strong but it is NOT designed for dynamic, or “shock” loading. Shock loading may tension a winch cable beyond its strength and cause the cable to break. The end of a broken winch cable under such high loading can cause SEVERE INJURY or DEATH to you and other bystanders.

  • Page 112: Winch Maintenance And Service Safety

    3. Never work on your winch without first disconnecting the battery connections to prevent accidental activation of the winch. 4. For your safety, always replace POLARIS winch parts (including the cable) with genuine POLARIS replacement parts available at your authorized POLARIS dealer, or other qualified person.

  • Page 113: Noise Emission Control System

    EMISSION CONTROL SYSTEMS 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 vehicle has a spark arrestor that was tested and qualified to be in accordance with the USFS standard 5100-1a.

  • Page 115: Periodic Maintenance

    PERIODIC MAINTENANCE Any qualified repair shop or person may maintain, replace or repair the emission control devices or systems on your vehicle. An authorized POLARIS dealer can perform any service that may be necessary for your vehicle. POLARIS also recommends POLARIS parts for emissions-related service, however equivalent parts can be used.

  • Page 116: Maintenance Intervals

    MAINTENANCE INTERVAL KEY SYMBOL DESCRIPTION Perform these procedures more often for vehicles subjected to severe use. Have an authorized Polaris dealer or other qualified person perform these services. 25 HOUR / 250 MILE (400 KM) SERVICE ITEM REMARKS XU /...
  • Page 117 MAINTENANCE ITEM REMARKS Lubricate all fittings, pivots, cables, etc. General Lubrication Inspect; clean external surfaces Radiator Shift Linkage Inspect Inspect for leaks, loose joints, and wear Shock Absorbers Steering Lubricate Throttle Body Intake Duct Inspect ducts for proper sealing / air leaks Inspect;...
  • Page 118 MAINTENANCE ITEM REMARKS Inspect coolant strength seasonally; pressure Cooling System test system yearly. Drive Belt (EBS / Non-EBS Inspect; replace as needed Clutches) Engine Breather Inspect, clean, replace if necessary Engine Mounts Inspect Engine Oil Change the oil and filter Exhaust Pipe / Silencer / Inspect;...
  • Page 119 MAINTENANCE 125 HOUR / 1250 MILE (2000 KM) SERVICE ITEM REMARKS XU / Inspect Brake Pad Wear Engine Oil Check level Front Gearcase Fluid Check level Inspect; cycle key to pressurize fuel pump; Fuel System Check check lines and fittings for leaks and abrasion. Transmission Oil Check level 150 HOUR / 1500 MILE (2400 KM) SERVICE...
  • Page 120 MAINTENANCE 175 HOUR / 1750 MILE (2800 KM) SERVICE ITEM REMARKS XU / Inspect Brake Pad Wear Engine Oil Check level Front Gearcase Fluid Check level Inspect; cycle key to pressurize fuel pump; Fuel System Check check lines and fittings for leaks and abrasion. Transmission Oil Check level 200 HOUR / 2000 MILE (3200 KM) SERVICE...
  • Page 121 MAINTENANCE ITEM REMARKS Change fluid Front Gearcase Fluid Cycle key to pressurize fuel pump; check for XU / Fuel System leaks at fill cap, fuel lines/rail and fuel pump. Lubricate all fittings, pivots, cables, etc. General Lubrication Inspect; clean external surfaces Radiator Shift Linkage Inspect...
  • Page 122 MAINTENANCE 250 HOUR / 2500 MILE (4000 KM) SERVICE ITEM REMARKS XU / Inspect Brake Pad Wear Drive Belt (Non-EBS Clutch) Inspect; replace as needed Engine Oil Check level Front Gearcase Fluid Check level Inspect; cycle key to pressurize fuel pump; Fuel System Check check lines and fittings for leaks and abrasion.
  • Page 123 MAINTENANCE 300 HOUR / 3000 MILE (4800 KM) SERVICE ITEM REMARKS Air Filter (Main Element) Inspect; replace as needed Check terminals; clean; test; replace as Battery needed XU / Inspect Brake Pad Wear Inspect; clean; replace as needed Cam Chain Tensioner Inspect bushings, rollers, wearable parts;...
  • Page 124 MAINTENANCE ITEM REMARKS Throttle Body Intake Duct Inspect ducts for proper sealing / air leaks Inspect; adjust; lubricate; replace if necessary Throttle Cable Transmission Oil Check level Wheel Bearings Inspect; replace as needed Inspect for wear, routing, security; apply Wiring dielectric grease to connectors subjected to water, mud, etc.
  • Page 125 MAINTENANCE ITEM REMARKS Steering Lubricate Throttle Body Intake Duct Inspect ducts for proper sealing / air leaks Inspect; adjust; lubricate; replace if necessary Throttle Cable Transmission Oil Check level 375 HOUR / 3750 MILE (6000 KM) SERVICE ITEM REMARKS XU / Inspect Brake Pad Wear Engine Oil...
  • Page 126 MAINTENANCE ITEM REMARKS Engine Breather Inspect, clean, replace if necessary Engine Mounts Inspect Engine Oil Change the oil and filter Exhaust Pipe / Silencer / Inspect; replace worn parts Joints Change fluid Front Gearcase Fluid Front / Rear Suspension Lubricate Cycle key to pressurize fuel pump;...
  • Page 127 MAINTENANCE 425 HOUR / 4250 MILE (6400 KM) SERVICE ITEM REMARKS XU / Inspect Brake Pad Wear Engine Oil Check level Front Gearcase Fluid Check level Inspect; cycle key to pressurize fuel pump; Fuel System Check check lines and fittings for leaks and abrasion. Transmission Oil Check level 450 HOUR / 4500 MILE (6800 KM) SERVICE...
  • Page 128 Cam Chain Tensioner Inspect bushings, rollers, wearable parts; Clutches (Non-EBS) clean; replace worn parts Cooling Hoses Inspect for leaks Replace coolant with Polaris 50/50 Extended- Cooling System Life Antifreeze. Drive Belt (EBS / Non-EBS Inspect; replace as needed Clutches) Engine Breather...
  • Page 129 MAINTENANCE ITEM REMARKS Lubricate all fittings, pivots, cables, etc. General Lubrication Inspect; clean external surfaces Radiator Shift Linkage Inspect XU / Replace or rebuild (if applicable) Shock Absorbers Non-ETC Models: Inspect; remove the clean- out bolt. Spark Arrestor ETC / California Models: Inspect; remove and clean the screen.

  • Page 130: Lubrication Guide

    MAINTENANCE LUBRICATION GUIDE Check and lubricate all components at the intervals outlined in the Periodic Maintenance Chart. Items not listed in the chart should be lubricated at the General Lubrication interval. The a-arms and lower control arms are lubricated at the factory, and no additional lubrication will be needed.

  • Page 131: Oil Recommendations

    POLARIS recommends the use of POLARIS PS-4 Full Synthetic 5W-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 5W-50 oil. Follow the manufacturer's recommendations for ambient temperature operation.

  • Page 132: Oil And Oil Filter Change

    MAINTENANCE OIL AND OIL FILTER CHANGE IMPORTANT Always change the oil filter whenever changing oil. See the Lubrication Guide section for fluid recommendations and capacities. Always change the oil and oil filter at the intervals outlined in the Periodic Maintenance Chart beginning on page 114.
  • Page 133 MAINTENANCE 10. Place an oil drain pan and shop towels beneath the oil filter. 11. Using an oil filter wrench (available from your POLARIS dealer), turn the filter counter-clockwise to remove it. Oil Filter Wrench PU-50105 12. Using a clean dry cloth, clean the filter sealing surface on the crankcase.

  • Page 134: Transmission Oil

    MAINTENANCE 18. Start the engine. Allow it to idle for one to two minutes. 19. Stop the engine and check for leaks. 20. Check the oil level. Add engine oil as needed to bring the level to the upper mark on the dipstick. See Oil Check section for proper procedure. 21.

  • Page 135: Front Gearcase (Demand Drive) Fluid

    NOTICE If the front gearcase is makes excessive noise during ADC operation, change the demand drive fluid. If the noise continues, please see your POLARIS dealer or other qualified service facility for service. Use the recommended fluid. Use of other fluids may result in improper operation of components.

  • Page 136: Fluid Change

    MAINTENANCE FLUID CHECK 1. Position the vehicle on a level surface. Remove the fill plug . Check the fluid level. 2. Add the recommended fluid as needed to bring the level to the bottom of the fill hole threads. 3. Reinstall the fill plug. Torque to specification.

  • Page 137: Power Steering Unit

    Check the coolant level and maintain as recommended by adding coolant to the recovery bottle. POLARIS recommends the use of POLARIS Antifreeze 50/50 Premix. This antifreeze is already premixed and ready to use. Do not dilute with water. See...

  • Page 138: Recovery Bottle Coolant

    3. Using a funnel, slowly add coolant through the radiator filler neck. 4. Reinstall the pressure cap. Use of a non-standard pressure cap will not allow the recovery system to function properly. Your POLARIS dealer can provide the correct replacement part.
  • Page 139 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.

  • Page 140: Side Panel Removal

    MAINTENANCE SIDE PANEL REMOVAL To remove the side panel, do the following: 1. Remove the seat. 2. Use a flat screwdriver to remove the plastic rivets securing the side panel. 3. Grasp the rear of the side panel near the rear cab. With a firm motion, pull the side panel outward to disengage the side panel from the grommets.

  • Page 141: Tire Tread Depth

    MAINTENANCE TIRES WARNING Operating your ATV 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 manual and on the labels on the vehicle. Always use original equipment size and type when replacing tires.

  • Page 142: Wheel Removal

    MAINTENANCE WHEEL REMOVAL WARNING Do not service axle nuts that have a cotter pin installed. Your authorized dealer can assist. 1. Stop the engine, place the transmission in park and lock the parking brake. 2. Loosen the wheel nuts slightly. 3.

  • Page 143: Wheel Nut Torque Specifications

    MAINTENANCE WHEEL NUT TORQUE SPECIFICATIONS Check the wheel nut torques occasionally and when they've been loosened for maintenance service. Lug Nut 30 ft-lbs (41 N·m) (Aluminum Front and Rear PLUS 70 degrees Wheels) 2-Piece Flange Nut 27 ft-lbs (37 N·m) Front and Rear (Steel Wheels)

  • Page 144: Toe Alignment

    1/4–1/2 inch (6–12 mm) toe out alignment. 5. Repeat the measurement procedure on the other side of the vehicle. 6. If you discover improper alignment, see your POLARIS dealer for service.

  • Page 145: Air Filter

    MAINTENANCE AIR FILTER It is recommended that the air filter is replaced annually. When riding in extremely dusty conditions, replacement is required more often. 1. Lift up on the rear of the seat. 2. Pull the seat back and free of the tabs. NOTICE When reinstalling seat, make sure the slots in the seat engage the tabs in the fuel tank.

  • Page 146: Fuse Replacement

    MAINTENANCE 5. Loosen the air filter hose clamp and remove air filter assembly. 6. Inspect the air filter and replace if necessary. If the filter has been soaked with fuel or oil, it must be replaced. 7. Reinstall the air filter on the main filter mount.

  • Page 147: Headlight Lamp Replacement

    5. Reassemble the pod. LED HEADLIGHT REPLACEMENT (IF EQUIPPED) On models equipped with LED headlights, if the headlights become inoperable, the entire assembly must be replaced by your authorized Polaris dealer or other qualified service facility.

  • Page 148: High Beam Adjustment

    MAINTENANCE HIGH BEAM ADJUSTMENT The headlight beam can be adjusted slightly upward or downward. Use the following procedure to make the adjustment. NOTE Image below is for reference only. Your model may differ slightly. 1. Position the vehicle on a level surface with the headlight approximately 25 ft. (7.6 m) from a wall .

  • Page 149: Headlight Housing Replacement

    MAINTENANCE BUMPER LIGHT ADJUSTMENT The low beam can be adjusted slightly upward or downward. To adjust the bumper headlight, do the following: 1. Loosen the Phillips® screw located at the rear of the headlamp. 2. Tilt the headlamp upward or downward.

  • Page 150: Lower Headlamp Replacement

    Refer to the specifications section for the recommended 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 use POLARIS-recommended spark plugs or their equivalent. ENGINE TORQUE SPECIFICATION 15 ft-lbs (20 Nm)

  • Page 151: Spark Plug Inspection

    MAINTENANCE SPARK PLUG INSPECTION Spark plug condition is indicative of engine operation. Check the spark plug firing end condition after the engine has been warmed up and the vehicle has been driven at higher speeds. Immediately check the spark plug for correct color.

  • Page 152: Vehicle Immersion

    If your vehicle becomes immersed, major engine damage can result if the machine is not thoroughly inspected. Take the vehicle in for service before starting the engine. Your POLARIS dealer can provide this service. If it's impossible to take your ATV to a dealer before starting it, follow the steps outlined below.

  • Page 153: Spark Arrestor

    MAINTENANCE SPARK ARRESTOR WARNING Do not perform clean out immediately after the engine has been run, as the exhaust system becomes very hot. Serious burns could result from contact with exhaust components. To reduce fire hazard, make sure that there are no combustible materials in the area when purging the spark arrestor.
  • Page 154 MAINTENANCE 2. Put the transmission in PARK (P) and start the engine. Purge the accumulated carbon from the system by momentarily revving the engine several times. 3. If some carbon is expelled, cover the exhaust outlet and lightly tap on the pipe around the clean out weld nut with a rubber mallet while revving the engine several more times.
  • Page 155 MAINTENANCE 4. If particles are still suspected to be in the muffler, back the machine onto an incline so the rear of the machine is one foot higher than the front. Put the transmission in PARK (P), lock the parking brake, and block the wheels to prevent roll back.
  • Page 156 MAINTENANCE 1. Remove the spark arrestor screen fasteners 2. Remove the spark arrestor from the end of the muffler.

  • Page 157: Pvt System

    • See your POLARIS dealer, or other qualified person, for service and repair assistance. • This PVT system is intended for use on POLARIS products only. Do not install it in any other product. • Always make sure the PVT housing is securely in place during operation.

  • Page 158: Pvt Drying

    MAINTENANCE For example, when operating at a ground speed of 3 MPH (5 km/h) in low range, the engine speed would be around 2700–3000 RPM. This is well above the engagement speed of 1500-1800 RPM. However, in high range at 3 MPH (5 km/ h), the engine would be running at only 1500–1800 RPM.

  • Page 159: Drive Belt Inspection

    MAINTENANCE PVT BREAK-IN (CLUTCHES / BELT) A proper break-in of the clutches and drive belt will ensure a longer life and better performance. Break in the clutches and belt by operating at slower speeds during the break-in period as recommended. Pull only light loads. Avoid aggressive acceleration and high speed operation during the break-in period.

  • Page 160: Battery Removal

    MAINTENANCE BATTERY WARNING 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. Always keep battery terminals and connections free of corrosion.
  • Page 161 MAINTENANCE...

  • Page 162: Battery Installation

    MAINTENANCE BATTERY INSTALLATION NOTICE Using a new battery that has not been fully charged can damage the battery and result in a shorter life. It can also hinder vehicle performance. Refer to the battery charging information in the Maintenance chapter before installing the battery.

  • Page 163: Battery Storage

    POLARIS recommends maintaining battery charge by using a POLARIS battery trickle charger or by charging once a month using the battery charge port The Polaris offered battery trickle charger can be left connected during the storage period, and will automatically charge the battery if the voltage drops below a pre-determined point.

  • Page 164: Battery Charging

    MAINTENANCE BATTERY CHARGING Read all instructions before proceeding with the installation of this battery. The battery is already filled with electrolyte and has been fully charged at the factory. Never pry the caps off or add any other fluid to this battery. The single most important thing about maintaining the battery is to keep it fully charged.

  • Page 165: Battery Identification

    It is important to identify the type of battery installed in the vehicle. Different types of batteries require different service procedures. Proper servicing and upkeep of the battery is very important for maintaining long battery life. All Polaris ORV models include either a Conventional battery or a Low Maintenance battery. CONVENTIONAL BATTERY •...
  • Page 166 LOW MAINTENANCE BATTERY BEST PRACTICES Some Polaris ORV models include either a Lead Acid or Absorbed Glass Mat (AGM) Low Maintenance battery. See the Service Manual for procedures on how to charge, maintain, and test a Lead Acid or AGM Low Maintenance battery.
  • Page 167 MAINTENANCE LOW MAINTENANCE BATTERIES CHARGING • Polaris recommends using a BatteryMINDer® 1.5 AMP (PN 2830404) charger, which can be ordered through your normal parts channel. • Nominal voltage is 12.6–12.8 Volts when fully charged. If the voltage falls below 12.5V, charge it immediately, or the battery runs the risk of sulfation.
  • Page 168 Follow the adjustment procedures exactly, or see your POLARIS dealer for service. 1. Remove the upper headlight pod.

  • Page 169: Cleaning And Storage

    • Always use clean cloths and pads for cleaning and polishing. Old or reused cloths and pads may contain dirt particles that will scratch the finish. POLISHING THE VEHICLE POLARIS recommends the use of common household aerosol furniture polish for polishing the finish on your POLARIS vehicle. Follow the instructions on the container.

  • Page 170: Storage Tips

    STABILIZE THE FUEL 1. Fill the fuel tank. 2. Add POLARIS Carbon Clean Fuel Treatment or POLARIS Fuel Stabilizer or equivalent fuel treatments or stabilizers. Follow the instructions on the container for the recommended amount. Carbon Clean removes water from fuel systems, stabilizes fuel and removes carbon deposits from pistons, rings, valves and exhaust systems.

  • Page 171: Inspect And Lubricate

    6. Reinstall the spark plug cap. 7. If POLARIS fuel system additive is not used, fuel tank, fuel lines, and injectors should be completely drained of gasoline. BATTERY MAINTENANCE See the Battery Storage and Battery Charging sections for storage and charging procedures.

  • Page 173: Specifications

    SPECIFICATIONS SPECIFICATIONS SPORTSMAN 450 H.O. / 450 H.O. EPS SPORTSMAN 450 H.O. / 450 H.O. EPS Maximum Weight Capacity 485 lbs. (220 kg) (operator, cargo, accessories) Manufactured Weight 450 HO: 714 lbs. (324 kg) 450 HO EPS: 736 lbs. (334 kg) Fuel Capacity 4.5 gal.
  • Page 174 1200 +/- 50 Spark Plug Type / Gap 5924 / 0.76-0.92 mm Lubrication System Wet Sump Driving System Type Automatic PVT (POLARIS Variable Transmission) Front Suspension Sealed MacPherson Ride® strut with 8.2" (21 cm) travel Rear Suspension Sealed Dual A-Arm, IRS 9.5" (24 cm) Travel...
  • Page 175 SPECIFICATIONS SPORTSMAN 450 H.O. UTILITY SPORTSMAN 450 H.O. UTILITY Maximum Weight Capacity 485 lbs. (220 kg) (operator, cargo, accessories) Manufactured Weight 767 lbs. (348 kg) Fuel Capacity 4.5 gal. (17 L) Engine Oil Capacity 2 qts. (1.9 L) Coolant Capacity 2.7 qts.
  • Page 176 1200 +/- 50 Spark Plug Type / Gap 5924 / 0.76-0.92 mm Lubrication System Wet Sump Driving System Type Automatic PVT (POLARIS Variable Transmission) Front Suspension Sealed MacPherson Ride® strut with 8.2" (21 cm) travel Rear Suspension Sealed Dual A-Arm, IRS 9.5" (24 cm) Travel...
  • Page 177 SPECIFICATIONS SPORTSMAN 570 / 570 EPS / PREMIUM SPORTSMAN 570 / 570 EPS / PREMIUM Maximum Weight Capacity 485 lbs. (220 kg) (operator, cargo, accessories) Manufactured Weight 570: 717 lbs. (325 kg) 570 EPS: 765 lbs. (347 kg) 570 EPS Premium: 761 lbs. (345 kg) Fuel Capacity 4.5 gal.
  • Page 178 1200 +/- 50 Spark Plug Type / Gap MR7F / 0.7-0.8 mm Lubrication System Wet Sump Driving System Type Automatic PVT (POLARIS Variable Transmission) Front Suspension Sealed MacPherson Ride® strut with 8.2" (21 cm) travel Rear Suspension Sealed Dual A-Arm, IRS 9.5" (24 cm) Travel...
  • Page 179 SPECIFICATIONS SPORTSMAN 570 UTILITY SPORTSMAN 570 / 570 EPS UTILITY Maximum Weight Capacity 485 lbs. (220 kg) (operator, cargo, accessories) Manufactured Weight 570: 767 lbs. (348 kg) 570 EPS: 799 lbs. (362 kg) Fuel Capacity 4.5 gal. (17 L) Engine Oil Capacity 2 qts.
  • Page 180 1200 +/- 50 Spark Plug Type / Gap MR7F / 0.7-0.8 mm Lubrication System Wet Sump Driving System Type Automatic PVT (POLARIS Variable Transmission) Front Suspension Sealed MacPherson Ride® strut with 8.2" (21 cm) travel Rear Suspension Sealed Dual A-Arm, IRS 9.5" (24 cm) Travel...
  • Page 181 SPECIFICATIONS SPORTSMAN 570 HD ULTIMATE UTILITY LE SPORTSMAN 570 HD ULTIMATE UTILITY LE Maximum Weight Capacity 485 lbs. (220 kg) (operator, cargo, accessories) Manufactured Weight 796 lbs. (361 kg) Fuel Capacity 4.5 gal. (17 L) Engine Oil Capacity 2 qts. (1.9 L) Coolant Capacity 2.7 qts.
  • Page 182 1200 +/- 50 Spark Plug Type / Gap MR7F / 0.7-0.8 mm Lubrication System Wet Sump Driving System Type Automatic PVT (POLARIS Variable Transmission) Front Suspension Sealed MacPherson Ride® strut with 8.2" (21 cm) travel Rear Suspension Sealed Dual A-Arm, IRS 9.5" (24 cm) Travel...
  • Page 183 SPECIFICATIONS SPORTSMAN 570 TRAIL SPORTSMAN 570 TRAIL Maximum Weight Capacity 485 lbs. (220 kg) (operator, cargo, accessories) Manufactured Weight 873 lbs. (396 kg) Fuel Capacity 4.5 gal. (17 L) Engine Oil Capacity 2 qts. (1.9 L) Coolant Capacity 2.7 qts. (2.5 L) Demand Drive Fluid Capacity 9 oz.
  • Page 184 1200 +/- 50 Spark Plug Type / Gap MR7F / 0.7-0.8 mm Lubrication System Wet Sump Driving System Type Automatic PVT (POLARIS Variable Transmission) Front Suspension Sealed MacPherson Ride® Dual A-Arm with 8.9 in. (22.6 cm) Travel Rear Suspension Sealed Dual A-Arm, IRS 9.5" (24 cm) Travel...
  • Page 185 SPECIFICATIONS SPORTSMAN 570 HUNT EDITION SPORTSMAN 570 HUNT EDITION Maximum Weight Capacity 485 lbs. (220 kg) (operator, cargo, accessories) Manufactured Weight 879 lbs. (399 kg) Fuel Capacity 4.5 gal. (17 l) Engine Oil Capacity 2 qts. (1.9 l) Coolant Capacity 2.7 qts.
  • Page 186 1200 +/- 50 Spark Plug Type / Gap MR7F / 0.7-0.8 mm Lubrication System Wet Sump Driving System Type Automatic PVT (POLARIS Variable Transmission) Front Suspension Sealed MacPherson Ride® strut with 8.9 in. (22.6 cm) travel Rear Suspension Sealed Dual A-Arm, IRS 9.5" (24 cm) Travel...

  • Page 187: Clutching Chart

    SPECIFICATIONS CLUTCHING CHART CLUTCH SETTINGS DRIVE CLUTCH DRIVEN CLUTCH ALTITUDE Clutch Clutch meters (feet) Shift Weight Driven Helix* Spring Spring EBS: 1323850 EBS: EBS: EBS: (36-67) 7045660 7045554 1323720 0-1800 (0-6000) Non-EBS: Non-EBS: Non-EBS: Non-EBS: 5632409 7043594 7041782 5132344 (25-52) EBS: 1327125 EBS:...

  • Page 189: Polaris Products

    POLARIS PRODUCTS POLARIS PRODUCTS LUBRICANTS / SERVICE PRODUCTS SIZE (QUANTITY) PRODUCT QUANTITY PART NUMBER 12 fl oz (355 mL) 2870791 aerosol Fogging Oil 1 qt (0.95 L) 2871517 1 qt (0.95 L) 2876244 2 qt (1.90 L) PS-4 2877490 1 gal (3.8 L) 2876245 1 qt (0.95 L)
  • Page 190 POLARIS PRODUCTS SIZE (QUANTITY) PRODUCT QUANTITY PART NUMBER 2.5 gal (9.5 L) 2872280 DOT 4 Brake Fluid — 2872189 Loctite® 565 Thread — 2871956 Sealant POLARIS Battery — 2859044 Tender Charger...

  • Page 191: Troubleshooting

    TROUBLESHOOTING TROUBLESHOOTING DIAGNOSTIC DISPLAY CODE DEFINITIONS Open Load:There is a break in the wires that lead to the item listed in the chart (injector, fuel pump, etc.), or the item has failed. Short-to-Ground:The wire is shorted to ground between the electronic control unit and the item listed in the chart.

  • Page 192: Diagnostic Codes

    TROUBLESHOOTING DIAGNOSTIC CODES COMPONENT CONDITION Gear Sensor Signal Voltage Too Low Voltage Too Low Signal Fault Injector 1 (MAG) Driver Circuit (SDI Part Load) Open/Grounded Driver Circuit Short to B+ Driver Circuit Grounded Injector 2 (PTO) Driver Circuit (SDI Part Load) Open/Grounded Driver Circuit Short to B+...
  • Page 193 TROUBLESHOOTING DIAGNOSTIC CODES COMPONENT CONDITION Idle Air Control Driver Circuit Open/Grounded Driver Circuit Short to B+ Driver Circuit Grounded Position Out of Range Starter Enable Driver Circuit 1321 Circuit Open/Grounded Driver Circuit Short 1321 to B+ Driver Circuit 1321 Grounded Chassis Relay Driver Circuit 520208...
  • Page 194 TROUBLESHOOTING DIAGNOSTIC CODES COMPONENT CONDITION Throttle Stuck 520194 Active Descent Driver Circuit 520203 Control System Open/Grounded Driver Circuit Short 520203 to B+ Driver Circuit 520203 Grounded Idle Speed Speed Too High 520211 Speed Too Low 520211 DIAGNOSTIC CODES COMPONENT CONDITION EPS MODELS ONLY Received Network Vehicle Speed...

  • Page 195: Drive Belt Wear/Burn

    TROUBLESHOOTING DIAGNOSTIC CODES COMPONENT CONDITION EPS MODELS ONLY Steering Torque Condition Exists 520224 Full Failure EPAS Inverter Data Valid But Temperature Above Normal Operational Range 520225 - Most Severe Level Data Valid But Above Normal Operating Range - 520225 Moderately Severe Level EPAS Data Erratic,...
  • Page 196 TROUBLESHOOTING POSSIBLE CAUSE SOLUTION Warm the engine at least 5 minutes. With the transmission in Insufficient warm-up at low neutral, advance the throttle to about 1/8 throttle in short bursts, 5 ambient temperatures to 7 times. The belt will become more flexible and prevent belt burning.

  • Page 197: Engine Doesn't Turn Over

    TROUBLESHOOTING ENGINE DOESN'T TURN OVER POSSIBLE CAUSE SOLUTION Low battery voltage Recharge the battery Loose battery connections Check all connections and tighten Loose solenoid connections Check all connections and tighten Loose electronic control box Inspect, clean, reinstall connectors connections ENGINE TURNS OVER, FAILS TO START POSSIBLE CAUSE SOLUTION Out of fuel...

  • Page 198: Engine Pings Or Knocks

    TROUBLESHOOTING ENGINE PINGS OR KNOCKS POSSIBLE CAUSE SOLUTION Poor quality or low octane fuel Replace with recommended fuel Incorrect spark plug gap or Set gap to specs or replace plug heat range ENGINE RUNS IRREGULARLY, STALLS OR MISFIRES POSSIBLE CAUSE SOLUTION Fouled or defective spark plug Inspect, clean and/or replace spark plug...

  • Page 199: Engine Stops Or Loses Power

    TROUBLESHOOTING ENGINE STOPS OR LOSES POWER POSSIBLE CAUSE SOLUTION Out of fuel Refuel Kinked or plugged fuel vent Inspect and replace line Water is present in fuel Replace with new fuel Fouled or defective spark plug Inspect, clean and/or replace spark plug Worn or defective spark plug Your authorized dealer can assist wires...

  • Page 201: Limited Warranty

    REGISTRATION At the time of sale, the Warranty Registration Form must be completed by your dealer and submitted to POLARIS within ten days of purchase. Upon receipt of this registration, POLARIS will record the registration for warranty. No verification of registration will be sent to the purchaser as the copy of the Warranty Registration Form will be your proof of warranty coverage.

  • Page 202: Warranty Coverage And Exclusions

    WARRANTY COVERAGE AND EXCLUSIONS LIMITATIONS OF WARRANTIES AND REMEDIES This POLARIS limited warranty excludes any failures that are not caused by a defect in material or workmanship. THIS WARRANTY DOES NOT COVER CLAIMS OF DEFECTIVE DESIGN. This warranty also does not cover acts of God, accidental damage, normal wear and tear, abuse or improper handling.

  • Page 203: Lubricants And Fluids

    MATERIALS, COMPONENTS, OR PRODUCTS. THE REMEDIES SET FORTH IN THIS WARRANTY ARE THE ONLY REMEDIES AVAILABLE TO ANY PERSON FOR BREACH OF THIS WARRANTY. POLARIS SHALL HAVE NO LIABILITY TO ANY PERSON FOR INCIDENTAL, CONSEQUENTIAL OR SPECIAL DAMAGES OF ANY DESCRIPTION, WHETHER ARISING OUT OF EXPRESS OR IMPLIED WARRANTY OR ANY OTHER CONTRACT, NEGLIGENCE, OR OTHER TORT OR OTHERWISE.

  • Page 204: How To Obtain Warranty Service

    IF YOU PURCHASE FROM A PRIVATE PARTY: If you purchase a POLARIS product from a private party, to be kept and used outside of the country in which the product was originally purchased, all warranty coverage will be denied. You must nonetheless register your product under your name and address with a local POLARIS dealer in your country to ensure that you receive safety information and notices regarding your product.

  • Page 205: Exported Products

    IS SOLD OUTSIDE THE COUNTRY OF THE SELLING DEALER'S AUTHORIZED LOCATION. This policy does not apply to products that have received authorization for export from POLARIS. Dealers may not give authorization for export. You should consult an authorized dealer to determine this product's warranty or service coverage if you have any questions.

  • Page 206: U.s.a. Epa Emissions Limited Warranty

    U.S.A. EPA EMISSIONS LIMITED WARRANTY This emissions limited warranty is in addition to the POLARIS standard limited warranty for your vehicle. Polaris Industries Inc. warrants that at the time it is first purchased, this emissions-certified vehicle is designed, built and equipped so it conforms with applicable U.S.
  • Page 207 The exclusive remedy for breach of this limited warranty shall be, at the exclusive option of POLARIS, repair or replacement of any defective materials, components or products. THE...

  • Page 208: California Residents

    WARRANTY Owners are responsible for performing the scheduled maintenance identified in the owner's manual. POLARIS may deny warranty claims for failures that have been caused by the owner's or operator's improper maintenance or use, by accidents for which POLARIS has no responsibility, or by acts of God.

  • Page 209: Manufacturer's Warranty Coverage

    As an owner you are responsible for presenting your OHRV-EVAP to a Polaris dealer as soon as a problem exists. The warranty repairs should be completed in a reasonable amount of time, not to exceed 30 days.

  • Page 211: Maintenance Log

    MAINTENANCE LOG MAINTENANCE LOG MAINTENANCE LOG Use the following chart to record periodic maintenance. DATE MILES (KM) TECHNICIAN SERVICE OR HOURS PERFORMED/ COMMENTS...
  • Page 212 MAINTENANCE LOG DATE MILES (KM) TECHNICIAN SERVICE OR HOURS PERFORMED/ COMMENTS...
  • Page 213 Camber and Caster....165 Cargo Warning......97 Active Descent Control (ADC) Clean the Exterior ....168 System ........41 Clothing........14 ADC 4X4 Mode (if equipped)..39 Clutching Chart ....... 185 Age Restrictions ......15 Cold Weather Operation....95 Air Filter Controls Tab ......
  • Page 214 Engine Backfires ..... 195 Handling Gasoline ..... 16 Engine Doesn't Turn Over ..195 Hauling Cargo......98 Engine Oil ......128 Headlight Lamp Replacement ..145 Engine Overheat Indicator ... 78 Headlight Switch ....... 34 Engine Pings or Knocks .... 196 Helmet ........
  • Page 215 Part Numbers ......187 Periodic Maintenance ....113 Physical Control of the Vehicle ..18 Physical Skills......24 Maintenance Polaris Products ...... 187 Air Filter......143 Polishing the Vehicle ....167 Intervals ......114 Poor Visibility......24 Spark Arrestor (ETC / EVAP / Power Steering Unit (Cleaning)...
  • Page 216 Stabilize the Fuel ..... 168 Stalling While Climbing a Hill ..20 Safe Operation Practices .... 81 Starting the Engine ....95 Safe Riding Gear ....... 13 Steering Assembly....135 Safety Labels and Locations ..27 Storage ......... 168 Age 16 Warning ..... 28 Storage Area ......
  • Page 217 Vehicle Immersion ....150 Warning Symbols ......8 Washing the Vehicle....167 Welcome Page ......3 Wet Fouled Plug...... 149 Wheel Installation ....140 Wheel Nut Torque Specifications......141 Wheel Removal....... 140 Winch Winch Operation ....103 Winch Safety Precautions ..101 Winch Cable Care ....
  • Page 219 • avoid paved surfaces - pavement may seriously affect handling and control SCAN CODE FOR PRODUCT AND SAFETY INFORMATION. FOLLOW ALL INSTRUCTIONS AND WARNINGS For your nearest Polaris dealer, call 1-800-POLARIS (765-2747) or visit www.polaris.com Polaris Inc. 2100 Highway 55 Part No.

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