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Polaris General XP 1000 2024 Owner's Manual

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2024
For Maintenance and Safety
OWNER'S
MANUAL
General XP 1000

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Summary of Contents for Polaris General XP 1000 2024

  • Page 1 2024 For Maintenance and Safety OWNER’S MANUAL General XP 1000...
  • 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 or visit: www.polaris.com/en-us/safety...
  • Page 3 2024 Owner’s Manual General XP 1000 Sport General XP 1000 Premium General XP 1000 Ultimate...
  • Page 4 Unless noted, trademarks are the property of Polaris Industries Inc. Recreational Off-Highway Vehicle Association® and ROHVA® are registered trademarks Recreational Off-Highway Vehicle Association. BatteryMINDer® is a registered trademark of VDC Electronics Inc. Loctite® is a registered trademark of Henkel Corporation. NYOGEL® is a registered trademark of Nye Lubricants, Inc.
  • 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: Table Of Contents

    Specifications ....107 POLARIS Products ....109 Troubleshooting ....111 Warranty .

  • Page 9: Introduction

    Failure to heed the warnings and safety precautions contained in this manual can result in severe injury or death. Your POLARIS vehicle is not a toy and can be hazardous to operate. This vehicle handles differently than cars, trucks or other off-road vehicles.
  • Page 10 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 (IF EQUIPPED) Some Polaris vehicles come equipped with a near-field communication (NFC) chip. The NFC chip is embedded in the Polaris emblem located at the front of the vehicle and seamlessly connects you to a digital platform of vehicle information and tools. See your dealer for more information.
  • Page 12 Digital Media Receiver PMX-P2 Rockford Corporation 9200 Series Display RC-7 Polaris Industries Inc. V2V Antenna 4017534 Laird 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 13 100 mW *Other transmitting radio frequencies may exist outside of EU markets. Hereby, Polaris Industries Inc. declares that the above radio equipment is in compliance with Directive 2014/53/EU. The full text of the EU declaration of conformity is available at the following internet address: https://www.polaris.com/en-us/radio-conformity/...
  • Page 14 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 15: Safety

    • Reduce the effectiveness of occupant protection systems, including the seatbelts and the Rollover Protective Structure (ROPS). • Make it illegal to own or operate your vehicle. POLARIS-authorized spark arresters, mufflers, and emissions control components are mandatory for ownership or operation in many areas.
  • Page 16 POLARIS recommends that you supervise younger drivers. Set rules and put limits on how, when, and where they are allowed to use this vehicle. For example, young drivers may need to have an adult in the vehicle with them and not be allowed to drive with their friends in the vehicle.
  • Page 17 SAFETY PREPARE VEHICLE FOR THE RIDE Before starting off, always perform the Pre-Ride Inspection. Failure to inspect and verify that the vehicle is in safe operating condition increases the risk of an accident, which can lead to serious injury or death. ITEM REMARK REFERENCE...
  • Page 18 SAFETY ITEM REMARK REFERENCE Exhaust Inspect spark arrester page 86 and clean if needed. – Vehicle Debris Remove grass, leaves, and other flammable material or debris, especially near the exhaust system. – Lock adjustable Do not adjust the steering wheel steering wheel while the vehicle is moving.
  • Page 19 Improper tire maintenance can lead to loss of control and an accident, which could result in serious injury or death. To reduce your risk of injury: • Maintain POLARIS recommended tire pressure. Check pressure before operating. Even if your vehicle has only been driven a short distance, the tire pressure readings can become higher.
  • Page 20 Use shatterproof goggles or a shatterproof helmet face shield. Such protective eyewear may reduce the risk of foreign material getting in your eyes and help prevent loss of vision. POLARIS recommends wearing approved Personal Protective Equipment (PPE) that have markings indicating they are designed to standards such as: •...
  • Page 21 SAFETY Always stay completely inside the vehicle and hold the steering wheel or hand holds. Body parts outside of the vehicle can be struck by passing objects or crushed during a rollover. Do not put any part of your body outside of the vehicle for any reason.
  • Page 22 SAFETY DRIVING GUIDELINES Drive Responsibly. This vehicle has higher ground clearance and other features to handle rugged terrain. It can be overturned in situations where some other vehicles may not. Abrupt maneuvers or aggressive driving, even on flat, open areas, can cause loss of control, rollovers, severe injury or death.
  • Page 23 Watching someone else go over a jump or go airborne does not mean you can safely do so. Polaris cannot determine whether any jump you may encounter is appropriate for this vehicle. Any jump, even a small one, could be poorly maintained, designed, or not suitable for this vehicle and may cause serious injury or death.
  • Page 24 SAFETY Improperly operating on hills can cause loss of control, rollover, or accident, which can lead to serious injury or death. Use extra care when operating on hills. Plan for rough terrain, ruts, and other changes in traction and terrain. Driving up hills Check the terrain before ascending a hill and make sure it is not too slippery or loose.
  • Page 25 SAFETY Riding in water / Falling into water Operating through deep or fast-flowing water can cause loss of traction, loss of control, overturning, or being swept away in water. You can be seriously injured or killed from entrapment and drowning. Never operate the vehicle in fast-flowing water or in water that exceeds the floor level of the vehicle.
  • Page 26 After any crash, rollover, or other accident, have a POLARIS dealer inspect the vehicle for possible damage, including seat belts, ROPS, brakes, suspension, and steering systems.
  • Page 27 Only recover a vehicle of equal or lesser size and weight. When recovering a disabled vehicle, place the disabled vehicle’s transmission in neutral. Do not move a disabled POLARIS vehicle faster than 10 mph (16 km/h). Operating, Idling, Or Parking Near Combustible Materials Engine, exhaust, and other vehicle components can be very hot during and after use.
  • Page 28 SAFETY After operation, inspect the vehicle for damage and debris to make sure the vehicle can be safely stored and operated again. Some things to inspect include: • Debris that could catch fire, such as mud/grass near the engine or exhaust system •...
  • Page 29 If any label becomes illegible or comes off, contact your POLARIS dealer to purchase a replacement. Replacement safety labels are provided by POLARIS at no charge.
  • Page 30 SAFETY SEAT BELT/DRIVE RESPONSIBLY WARNING (7185097) WARNING Improper vehicle use can result in SEVERE INJURY or DEATH BE PREPARED • Fasten seat belts. • Wear an approved helmet and protective gear. • ALWAYS use cab nets and/or doors. • Each rider must be able to sit with back against seat, feet flat on the floor, and hands on steering wheel or hand holds.
  • Page 31 Improper service or maintenance of this PVT system can result in vehicle damage, SEVERE INJURY or DEATH. Always look for and remove debris inside and around clutch and vent system when replacing belt. Read owner’s manual or see authorized POLARIS dealer.
  • Page 32 SAFETY LOAD / PASSENGER / TIRE PRESSURE WARNING The Load/Passenger/Tire Pressure warning decal is located on the front panel of the rear cargo box WARNING • Never carry passengers in cargo box. • Passengers can be thrown off. This can cause serious injury or death. IMPROPER TIRE PRESSURE OR OVERLOADING CAN CAUSE LOSS OF CONTROL RESULTING IN SERIOUS INJURY OR DEATH.
  • Page 33 The Air Filter Caution label is located on the air filter housing. CAUTION Use a Polaris approved air filter. The use of a non-Polaris approved air filter may cause engine damage. Before installing filter, ensure there is no dirt or debris in the clean side of the intake tube.

  • Page 35: Features And Controls

    FEATURES AND CONTROLS FEATURES AND CONTROLS COMPONENT LOCATIONS Console Receiver Hitch Headlights ROPS Cab Frame Radiator Cargo Box Front Bumper/ Brush Guard/Lighted Bar (if Taillights equipped) PVT Intake Screen CV Boot/Rear Caliper Muffler (Spark Arrester)
  • Page 36 Always shift when the vehicle is stationary and the engine is at idle. Maintaining shift linkage adjustment is important to assure proper transmission function. Your POLARIS dealer, or other qualified person, can assist in resolving any shifting problems. USING LOW RANGE Always shift into low gear for any of the following conditions.
  • Page 37 FEATURES AND CONTROLS SWITCHES IGNITION SWITCH The engine is off. Electrical circuits are off, except Acc, 12V. The engine is off. Powers the gauge and terminal block. ACCESSORY Check engine and steering warning indicators will appear (if equipped) on the gauge in this mode, but will turn off when the vehicle is started if no issues are present.
  • Page 38 FEATURES AND CONTROLS LIGHT SWITCH The ignition switch key must be in the ON/RUN position to operate the headlights. Press the top of the switch to place the headlights on high beam. Move the switch to the center position to place the headlights on low beam.
  • Page 39 FEATURES AND CONTROLS BUMPER-MOUNTED LIGHT BAR SWITCH (IF EQUIPPED) NOTICE The bumper-mounted light bar should only be used when operating off-road. To activate the bumper-mounted light bar, the ignition switch must be in the ACC or ON position. Press the top of the rocker switch to activate the bumper-mounted light bar.
  • Page 40 FEATURES AND CONTROLS FOOT PEDALS BRAKE PEDAL Depress the brake pedal to slow or stop the vehicle. Apply the brakes while starting the engine. When the brake pedal is depressed, the brake light comes on. Check the brake light before each ride. 1.
  • Page 41 FEATURES AND CONTROLS SEATS SEAT BELTS This vehicle is equipped with three-point lap and diagonal seat belts for the operator and any passengers. Always make sure the seat belts are secured for all riders before operating. The driver’s seat belt is equipped with a seat belt interlock.
  • Page 42 FEATURES AND CONTROLS SEAT BELT INSPECTION WARNING Failure to perform regular inspection can reduce the effectiveness of the seat belt during a crash and could result in serious injury or death. Inspect all seat belts for proper operation before each use of the vehicle. 1.
  • Page 43 EPS has shut down. Turn the key off and on to reset the unit. If the light remains on after starting the engine, the EPS system is inoperative. See your POLARIS dealer, or other qualified person, as soon as possible for repair. Continued operation could result in permanent damage to the EPS unit and increased steering effort.
  • Page 44 Always inspect doors and latches for wear and damage before each use of the vehicle. Promptly replace any worn or damaged parts with new parts available from your authorized POLARIS dealer, or other qualified person. FUEL CAP NOTICE Never use fuel blends with more than 10% ethanol.
  • Page 45 FEATURES AND CONTROLS INSTRUMENT CLUSTER NOTICE High water pressure may damage components. Wash the vehicle by hand or with a garden hose using mild soap. Certain products, including insect repellents and chemicals, will damage the speedometer lens and other plastic surfaces.
  • Page 46 FEATURES AND CONTROLS SPEEDOMETER The speedometer displays vehicle speed in either miles per hour (MPH) or kilometers per hour (km/h). TACHOMETER The tachometer displays engine speed in revolutions per minute (RPM). MODE BUTTON Press and hold the MODE button to enter or exit the settings menu. Press and release the MODE button to cycle through Area 1 modes and to select an item.
  • Page 47 Steering (EPS) ON position. If the light remains on, the EPS system is Warning (if inoperative. See your POLARIS dealer, or other qualified equipped) person, as soon as possible for repair. Continued operation could result in permanent damage to the EPS unit and increased steering effort.
  • Page 48 This indicator shows whether 2X4 or AWD is active. Service A flashing wrench symbol alerts the operator that the preset Indicator service interval has been reached. Your POLARIS dealer, or other qualified person, can provide scheduled maintenance. See page 51 for resetting instructions. Fuel Gauge The segments of the fuel gauge show the level of fuel in the fuel tank.
  • Page 49 FEATURES AND CONTROLS MODE INFORMATION DISPLAYS The rider information center contains three areas that display mode information. Description Area 1 Modes Engine Temperature Temperature of engine coolant Vehicle Speed Speed of vehicle Tachometer Engine speed (RPM) Description Area 2 Modes Odometer The odometer records and displays the distance traveled by the vehicle.
  • Page 50 FEATURES AND CONTROLS ACCESSING MENUS AND OPTIONS GAUGE SETTINGS MENU Press and release the MODE button to cycle through the Area 1 modes until the desired default mode displays. See the Mode Information Displays section for details. Press and hold the MODE button to enter the settings menu. The OPTIONS screen will display for a few seconds.
  • Page 51 FEATURES AND CONTROLS BACKLIGHT BRIGHTNESS The information center backlight can be set to either blue or red. 1. Press and hold the MODE button to enter the settings menu. 2. Press either toggle button to cycle to the “BL LEVEL” option. Press MODE to select.
  • Page 52 FEATURES AND CONTROLS DISPLAY UNITS (STANDARD/METRIC) 1. Press and hold the MODE button to enter the settings menu. 2. Press either toggle button to cycle to the desired “UNITS” option (distance, temperature or volume). Press MODE to select. 3. Press either toggle button to cycle to the desired setting. 4.
  • Page 53 FEATURES AND CONTROLS PROGRAMMABLE SERVICE INTERVAL The service interval counter is programmed to 25 hours at the factory. As hours of engine operation increase, the counter decreases. The wrench icon will flash for about 10 seconds when the counter reaches zero (0), and each time the key is turned on thereafter, until the counter is reset.
  • Page 54 FEATURES AND CONTROLS ENGINE ERROR CODES The error screen displays only when the CHECK ENGINE indicator is on or when it goes on and off during one ignition cycle. Error codes are not stored. When the key is turned OFF, the code and message is lost, but will reappear if the fault reoccurs after restarting the engine.

  • Page 55: Operation

    OPERATION OPERATION 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 56 This fuel will provide the best engine performance (starting, run quality, fuel economy, and power) and durability. Octane Rating Polaris recommends a minimum of 87 Octane (R+M/2) rated gasoline. Using lower octane gasoline could result in engine damage. Ethanol Content Polaris recommends gasoline containing up to 10% ethanol (E10).
  • Page 57 OPERATION Polaris recommends using gasoline that is purchased during the season the vehicle is being used, especially summer vs. winter. Between seasons, refineries typically change the gasoline blend to avoid temperature induced engine performance issues. Winter blend gasoline improves engine starting in cold weather and summer blend gasoline helps prevent vapor lock issues in hot weather.
  • Page 58 OPERATION STOPPING THE ENGINE 1. Release the throttle pedal completely and brake to a complete stop. 2. Place the transmission in PARK. 3. Turn the key to the OFF position. 4. Slowly release the brake pedal and make sure the transmission is in PARK before exiting the vehicle.
  • Page 59 OPERATION All-Wheel Drive (AWD) Differential Lock Differential Unlock Engage the AWD before getting into conditions where front wheel drive may be needed. If the rear wheels are spinning, release the throttle before switching to AWD. NOTICE Switching to AWD while the rear wheels are spinning may cause severe drive shaft and clutch damage.
  • Page 60 OPERATION LOCKING THE DIFFERENTIAL Move the rocker switch to the center position to lock the differential and operate in two wheel drive (2WD). Locking the differential in slippery or low traction conditions helps improve traction. When the rear differential is locked, both rear wheels rotate at the same speed.
  • Page 61 OPERATION HAULING CARGO WARNING Hauling cargo improperly can alter vehicle handling and may cause loss of control or brake instability, which can result in serious injury or death. WARNING Always follow these precautions when hauling cargo: • Never exceed the maximum weight capacity of the vehicle. When determining the weight you are adding to the vehicle, include the weight of the operator, passengers, non-factory installed accessories, loads in the rack or box and the load on the trailer tongue.
  • Page 62 Your POLARIS vehicle has been designed to carry or tow specific capacities. Always read and understand the load distribution warnings listed on the warning labels. The total load (operator, passengers, non-factory installed accessories, cargo and weight on hitch) must not exceed the maximum weight capacity of the vehicle.
  • Page 63 OPERATION 4. Do not tow more than the recommended weight for the vehicle. See the towing capacity chart below and the Specifications section for towing values. 5. Attach a trailer to the trailer hitch bracket only. Do not attach a trailer to any other location, which could result in loss of control of the vehicle.
  • Page 64 OPERATION BELT LIFE To extend belt life, use low gear when hauling or towing heavy cargo. DUMPING THE CARGO BOX 1. Select a level site to dump the cargo box. Do not attempt to dump or unload the vehicle while parked on an incline. 2.
  • Page 65 OPERATION 5. Stand clear and pull one of the cargo box release levers upward. Lift the front of the cargo box to dump the cargo. 6. Lower the cargo box and push down securely to latch. WARNING Operating the vehicle while the cargo box is raised could result in severe injury. The box could close unexpectedly and cause injury to the driver or passenger.

  • Page 67: Emission Control Systems

    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 arrester that was tested and qualified to be in accordance with the USFS standard 5100-1D.

  • Page 69: Maintenance

    Any qualified repair shop or person may maintain, replace or repair the emission control devices or systems on your vehicle. An authorized 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 70 MAINTENANCE CHART 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. WARNING Improperly performing the procedures marked with a D could result in component failure and lead to serious injury or death.
  • Page 71 MAINTENANCE MAINTENANCE INTERVAL (WHICHEVER COMES FIRST) MILES (KM) ITEM HOURS CLNDR REMARKS Shift Linkage Inspect, lubricate, adjust 50 H (800) Steering 50 H Lubricate (800) Front and Rear 50 H Lubricate (800) Stabilizer Bars Inspect for free movement; Throttle Pedal 50 H (800) replace pedal as needed...
  • Page 72 MAINTENANCE MAINTENANCE INTERVAL (WHICHEVER COMES FIRST) MILES (KM) ITEM HOURS CLNDR REMARKS 1000 Remove and grease Drive shafts 100 H 12 M (1600) 1000 Spark plug Inspect; replace as needed 100 H 12 M (1600) Inspect for wear, routing, security; 1000 apply dielectric grease to Wiring...
  • Page 73 MAINTENANCE ITEM LUBE METHOD Engine Oil PS-4 5W-50 4-Cycle Oil Add to proper level on dipstick. See page 73. Brake Fluid DOT 4 Brake Fluid Maintain level between fill lines. See page 89. Main Gearcase Oil AGL Gearcase Lubricant & See page 77.
  • Page 74 POLARIS recommends the use of POLARIS PS-4 5W-50 4-Cycle Oil or a similar oil. Refer to the Specifications section for capacities. Oil may need to be changed more frequently if POLARIS PS-4 engine oil is not used. Follow the manufacturer's recommendations for ambient temperature operation.
  • Page 75 MAINTENANCE OIL CHECK Always check the oil when the engine is cold. If the engine is hot when the oil is checked, the level will appear to be overfull. CAUTION Always remove all cargo from the cargo box before lifting the box to access engine components.
  • Page 76 MAINTENANCE OIL AND FILTER CHANGE Always change the oil and filters at the intervals outlined in the Periodic Maintenance Chart section. Always change the oil filter whenever changing oil. The crankcase drain plug is located on the bottom of the crankcase. Access the drain plug through the access hole in the skid plate under the crankcase (see next page).
  • Page 77 MAINTENANCE 12. Lubricate the o-ring on the new filter with a film of fresh engine oil. Check to make sure the o-ring is in good condition. 13. Install the new filter and turn by hand until the filter gasket contacts the sealing surface, then turn an additional 3/4 turn.
  • Page 78 Periodic Maintenance Chart section. Refer to the Gearcase Specifications Chart for recommended lubricants, capacities and torque specifications. See page 109 for the part numbers of POLARIS products. OIL CHECK The fluid check/fill plug is located on the rear of the gearcase. Maintain the oil level even with the bottom of the plug hole threads.
  • Page 79 Refer to the Gearcase Specifications Chart for recommended lubricants, capacities and torque specifications. See Lubricants/ Service Products for the part numbers of POLARIS products. OIL CHECK The front gearcase fill plug is located on the right side of the front gearcase.
  • Page 80 MAINTENANCE...
  • Page 81 Refer to the Specifications section for the recommended spark plug type for your vehicle. Always torque spark plugs to specification. NOTICE Using non-recommended spark plugs can result in serious engine damage. Always use POLARIS-recommended spark plugs or their equivalent. SPARK PLUG GAP / TORQUE ELECTRODE GAP PLUG TORQUE 0.7-0.8 mm...
  • Page 82 MAINTENANCE NORMAL PLUG The normal insulator tip is gray, tan or light brown. There will be few combustion deposits. The electrodes are not burned or eroded. This indicates the proper type and heat range for the engine and the service. The tip should not be white.
  • Page 83 ADDING OR CHANGING COOLANT POLARIS recommends the use of POLARIS Antifreeze 50/50 Premix. This antifreeze is already premixed and ready to use. Do not dilute with water. To ensure that the coolant maintains its ability to protect the engine, we recommend that the system be completely drained every five (5) years and fresh Antifreeze 50/50 Premix added.
  • Page 84 6. Reinstall the coolant bottle cap. If coolant must be added often, or if the overflow bottle runs completely dry, there may be a leak in the system. Your POLARIS dealer, or other qualified person, can inspect the cooling system.
  • Page 85 • See your dealer or other qualified service person as outlined in the owner's manual. • 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 86 Take the vehicle in for service before starting the engine. Your POLARIS dealer, or other qualified person, can provide this service. If it's impossible to take your POLARIS vehicle to a dealer before starting it, follow the steps outlined below:...
  • Page 87 6. Attempt to start the engine. If necessary, repeat the drying procedure. 7. Take the vehicle in for service as soon as possible, whether you succeed in starting it or not. Your POLARIS dealer, or other qualified person, can provide the required service.
  • Page 88 MAINTENANCE FILTER SYSTEMS AIR FILTER Always change the air filter at the intervals outlined in the Periodic Maintenance Chart. Service the air filter more frequently if the vehicle is operated in wet conditions or at high throttle for extended periods. 1.
  • Page 89 MAINTENANCE 1. Place the transmission in PARK. 2. Remove the arrestor retaining bolt and nut. 3. Remove the arrestor from the end of the muffler. 4. Use a non-synthetic brush to clean the arrestor screen. A synthetic brush may melt if components are warm. If necessary, blow debris from the screen with compressed air.
  • Page 90 MAINTENANCE...
  • Page 91 MAINTENANCE BRAKES The front and rear brakes are hydraulic disc type brakes activated by the brake pedal. WARNING Do not perform maintenance immediately after the vehicle has been operated, as the brake system may become very hot. Serious burns could result from contact with hot brake components.
  • Page 92 MAINTENANCE BRAKE INSPECTION WARNING Do not apply WD-40® or any petroleum product to brake discs. These types of products are flammable and may also reduce the friction between the brake pad and caliper. 1. Check the brake system for fluid leaks. 2.
  • Page 93 1.5 inches (38.1 mm) Rear 0.4 inches (10.2 mm) Your POLARIS dealer, or other qualified person, can provide the tool required to make suspension adjustments. 1. Elevate the vehicle to allow the suspension to fully extend. 2. Loosen the jam nut and back it away from the adjusting ring.
  • Page 94 MAINTENANCE FRONT/REAR SHOCK COMPRESSION The compression damping adjustment is located on the shock ‘Piggyback’ reservoir of each shock. Damping adjustments can be made without using any tools. Turn the adjuster knob clockwise to increase compression damping. Turn the adjuster knob counter-clockwise to decrease compression damping. FACTORY COMPRESSION SETTINGS Front Shock 8 clicks from full hard...
  • Page 95 Improper tire inflation or the use of non-standard size or type of tires may adversely affect vehicle handling, which could result in vehicle damage or personal injury. Always maintain proper tire pressure. Always use POLARIS approved size and type of tires for this vehicle when replacing tires.
  • Page 96 MAINTENANCE WHEEL INSTALLATION WARNING Improperly installed wheels can adversely affect tire wear and vehicle handling, which can result in serious injury or death. Always ensure that all nuts are torqued to specification. Do not service axle nuts that have a cotter pin installed.
  • Page 97 MAINTENANCE FUSES If the engine stops or will not start, or if you experience other electrical failures, a fuse may need replacement. Locate and correct any short circuits that may have caused the blown fuse, then replace the fuse. Raise the driver’s seat and remove the access panel to access the fuse center.
  • Page 98 MAINTENANCE HEADLIGHT BEAM ADJUSTMENT 1. Place the vehicle on a level surface with the headlight approximately 25 ft. (7.6 m) from a wall. 2. Place the transmission in 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.
  • Page 99 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. Your vehicle has a low-maintenance battery.
  • Page 100 MAINTENANCE 5. Connect and tighten the red (positive) cable first. 6. Connect and tighten the black (negative) cable last. 7. Verify that cables are properly routed.
  • Page 101 If you do not drive the vehicle for more than TWO WEEKS, Polaris recommends using a BatteryMINDer® 2012 AGM - 2 AMP charger (PN 2830438), which can be ordered through your dealer.
  • Page 102 MAINTENANCE STATE OF VOLTAGE (DC) ACTION CHARGE TIME* CHARGE 100% 12.8-13.0 volts None, check None required monthly 75%-100% 12.6-12.8 volts May need slight 3-6 hours charge, if no charge given, check in 2 weeks 50%-75% 12.3-12.6 volts Needs charge 5-11 hours 25%-50% 12.0-12.3 volts Needs charge...
  • Page 103 Certain products, including insect repellents and chemicals, will damage plastic surfaces. Do not allow these types of products to contact the vehicle. The best and safest way to clean your POLARIS vehicle is with a garden hose and a pail of mild soap and water.
  • Page 104 • Never use lubricant on any seat belt component. • Do not use a pressure washer to clean the seat belts. If warning and safety labels are damaged, contact your POLARIS dealer for free replacement. Grease all zerk fittings (if applicable) immediately after washing. Allow the engine to run for a while to evaporate any water that may have entered the engine or exhaust system.
  • Page 105 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 106 6. Reinstall the spark plug caps. 7. If POLARIS fuel system additive is not used, fuel tank, fuel lines, and injectors should be completely drained of gasoline. STORAGE AREA / COVERS Be sure the storage area is well ventilated.
  • Page 107 MAINTENANCE REMOVAL FROM STORAGE WARNING Engine exhaust contains poisonous carbon monoxide and can cause loss of consciousness or death. Never run an engine in an enclosed area. 1. Check the battery electrolyte level and charge the battery if necessary. Install it in the vehicle.
  • Page 108 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...

  • Page 109: Specifications

    SPECIFICATIONS SPECIFICATIONS GENERAL XP 1000 Maximum Weight Capacity (including operator, 1000 lbs. (454 kg) passenger, cargo, non-factory installed accessories) Dry Weight Sport: 1668 lbs. (756 kg) Premium: 1679 lbs. (762 kg) Ultimate: 1718 lbs. (779 kg) Test GVW - Rollover Protection System (ROPS) 3000 lbs.
  • Page 110 ANSI®/ROHVA® 1–2016 standard. CLUTCHING (GENERAL) See your POLARIS dealer or qualified person for clutching specifications.

  • Page 111: 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 112 POLARIS PRODUCTS SIZE (QUANTITY) PRODUCT QUANTITY PART NUMBER 12 fl oz (355 mL) bottle Carbon Clean 2871326 16 fl oz (473 mL) 2870652 Fuel Stabilizer 2.5 gal (9.5 L) 2872280 DOT 4 Brake Fluid — 2872189 Loctite® 565 Thread —...

  • Page 113: Troubleshooting

    TROUBLESHOOTING TROUBLESHOOTING DRIVE BELT WEAR/BURN POSSIBLE CAUSE SOLUTION Driving onto a pickup or tall Use low range during loading. trailer in high range Starting out going up a steep Use low range. incline Driving at low RPM or ground speed – 3–7 mph (4.8–11.3 Drive at a higher speed or use low range more frequently.
  • Page 114 TROUBLESHOOTING ENGINE DOESN'T TURN OVER POSSIBLE CAUSE SOLUTION Low battery voltage Recharge the battery. Loose battery Check all connections and tighten. connections Loose solenoid Check all connections and tighten. connections Loose electronic control Inspect, clean, reinstall connectors. box connections ENGINE TURNS OVER, FAILS TO START POSSIBLE CAUSE SOLUTION Out of fuel...
  • Page 115 TROUBLESHOOTING POSSIBLE CAUSE SOLUTION Mechanical failure Your authorized dealer can assist Loose ignition connections Check all connections and tighten Water present in fuel Replace with fresh recommended fuel 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...
  • Page 116 Replace with new fuel Fouled or defective spark plug Inspect, clean and/or replace spark plug Worn or defective spark plug Your POLARIS dealer, or other qualified person, can assist wires Incorrect spark plug gap or Set gap to specs or replace plug...

  • Page 117: 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 118 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 119 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 120 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. However, we encourage you to promptly register your product at your local authorized POLARIS dealer to receive safety information and notice regarding your product.
  • Page 121 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 122 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 123 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 124 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 125 California regulations and may void this limited emissions warranty offered by the manufacturer. POLARIS Industries Inc. warrants that at the time it is purchased, this vehicle is: 1. Designed, built, and equipped so as to conform, at the time of sale, with all applicable California evaporative emissions regulations.
  • Page 126 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 127 If the part fails before the first scheduled replacement point, the part must be repaired or replaced by POLARIS according to subdivision (4). Any such part repaired or replaced under warranty must be warranted for the remainder of the period prior to the first scheduled replacement point for the part.
  • Page 128 OHRV. Such use, in and of itself, will not be grounds for disallowing a warranty claim made under the provisions of this Article. POLARIS is not liable under the provisions of this Article to warrant failures of warranted parts caused by the use of an add-on or modified part(s) unless such part(s) are also warranted.

  • Page 129: Maintenance Log

    MAINTENANCE LOG MAINTENANCE LOG MAINTENANCE LOG Use the following chart to record periodic maintenance. DATE MILES (KM) TECHNICIAN SERVICE PERFORMED / OR HOURS COMMENTS...
  • Page 131 Adding or Changing Coolant ..81 Display Units, Standard/Metric ..50 Air Filter........86 Drive Belt Wear/Burn....111 Air Filter / Air Box..... 103 Drivetrain Break-In..... 53 All Wheel Drive/Rear Drying the Transmission....84 Differential System ....56 Auxiliary Outlet......37 Axle and Wheel Nut Torque Specifications......
  • Page 132 Fluid Part Numbers ....109 Load Capacity......59 Fog the Engine ....... 104 Lubricants / Service Products ..109 Fouled Plugs ......80 Lubrication Recommendations ..70 Front Gearcase ......77 Front/Rear Spring Preload ... 91 Fuel Cap........42 Fuel Recommendation....54 Main Gearcase ......
  • Page 133 Spark Plug Recommendations ..79 Plugs, Fouled ......80 Specifications ......107 Plugs, Spark......79 Spring Preload ......91 Polaris Products ...... 109 Stabilize the Fuel ..... 103 POLARIS Variable Starting the Engine ....55 Transmission System....83 Steering Wheel Inspection ... 85 Polishing the Vehicle ....
  • Page 134 Warning Symbols ......8 Washing the Vehicle....101 Water, Immersion of Vehicle..84 Welcome Page ......3 Wet Fouled Plug......80 Wheel Installation ...... 94 Wheel Nut Inspection ....93 Wheel Nut Torque...... 93 Wheel Removal......93 Winch Switch (if equipped) ..36...
  • Page 136 For your nearest Polaris dealer, call 1-800-POLARIS (765-2747) or visit www.polaris.com Polaris Industries Inc. 2100 Highway 55 Part No. 9941301 Rev 01 Medina, MN 55340 Printed in USA...

This manual is also suitable for:

General xp 1000 sport 2024General xp 1000 premium 2024General xp 1000 ultimate 2024

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