Polaris Pro XD 4000D AWD (2021) Manual

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OWNER’S

MANUAL

For Maintenance and Safety

POLARIS PRO XD

2021

WARNING

Operating, servicing, and maintaining a passenger vehicle or off-road

vehicle can expose you to chemicals including engine exhaust, carbon

monoxide, phthalates, and lead, which are known to the State of California

to cause cancer and birth defects or other reproductive harm. o minimize T

exposure, avoid breathing exhaust, do not idle the engine exc e t as p

necessary , service your vehicle in a well-ventilated area and wear gloves

or wash your hands frequently when servicing your vehicle.

For more information go to www .P65W arnings.ca.gov/passenger-vehicle.

!WARNING

Read, understand, and follow all of the instructions and safety

precautions in this manual and on all product labels.

Failure to follow the safety precautions

could result in serious injury or death.

For videos and more information

about a safe riding experience with

your Polaris vehicle, scan this QR

Code ® with your smartphone.

WARNING

Breathing diesel engine exhaust exposes you to chemicals known to the

State of California to cause cancer and birth defects or other reproductive

harm. Always start and operate the engine in a well ventilated area. If in

an enclosed area, vent the exhaust to the outside. Do not modify or

tamper with the exhaust system. Do not idle the engine except as

necessary.

For more information go to www.P65Warnings.ca.gov/diesel.

2021 Owner’s Manual

POLARIS PRO XD 2000D AWD

POLARIS PRO XD 4000D AWD

Unless noted, trademarks are the property of Polaris, Inc.

Loctite® is a registered trademark of Henkel Corporation. NYOGEL® is a

registered trademark of Nye Lubricants, Inc. Tread Lightly® is a registered

trademark of the United States Department of Agriculture. QR Code® is a

registered trademark of DENSO WAVE INCORPORATED. WD-40® is

registered to WD-40 Manufacturing Company.

based on the latest product information at the time of publication. Due to

constant improvements in the design and quality of production components,

some minor discrepancies may result between the actual vehicle and the

information presented in this publication. Depictions and/or procedures in this

publication are intended for reference use only. No liability can be accepted

for omissions or inaccuracies. Any reprinting or reuse of the depictions and/or

procedures contained within, whether whole or in part, is expressly

prohibited.

The original instructions for this vehicle are in English. Other languages are

provided as translations of the original instructions.

Printed in U.S.A.

9940219 R01

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. We believe POLARIS sets a standard of excellence for all utility and

recreational vehicles manufactured in the world today. Many years of experience

have gone into the engineering, design, and development of your POLARIS

vehicle, making it the finest machine we’ve ever produced.

For safe and enjoyable operation of your vehicle, be sure to follow the

instructions and recommendations in this owner’s manual. Your manual contains

instructions for minor maintenance, but information about major repairs is

outlined in the POLARIS Service Manual and can be performed by a factory

certified Master Service Dealer (MSD) technician.

Your POLARIS dealer knows your vehicle best and is interested in your total

satisfaction. Your POLARIS dealership can perform all of your service needs

during and after the warranty period.

For the most up-to-date owner’s manual visit https://www. polaris. com/en-us/

owners-manuals.

WELCOME

Introduction . . . . . . . . . . . . . . . . . . . . 7

Safety . . . . . . . . . . . . . . . . . . . . . . 11

Features and Controls . . . . . . . . . . . . . . 33

Operation . . . . . . . . . . . . . . . . . . . . 63

Winch Guide. . . . . . . . . . . . . . . . . . . 89

Emission Control Systems . . . . . . . . . . . . . 99

Maintenance . . . . . . . . . . . . . . . . . . 101

Specifications . . . . . . . . . . . . . . . . . . 167

POLARIS Products . . . . . . . . . . . . . . . . 171

Troubleshooting . . . . . . . . . . . . . . . . . 173

Warranty . . . . . . . . . . . . . . . . . . . . 177

Maintenance Log . . . . . . . . . . . . . . . . 189

INTRODUCTION

IMPORTANT INFORMATION

WARNING

Failure to follow the warnings contained in this manual can result in severe

injury or death.

This vehicle is not a toy and can be hazardous to operate. This vehicle handles

differently than other vehicles. A collision or rollover can occur quickly, even

during routine maneuvers, if you fail to take proper precautions.

• Read this owner’s manual. Understand all safety warnings, precautions and

operating procedures before operating the vehicle. Keep this manual with

the vehicle at all times.

• This vehicle is an ADULT VEHICLE ONLY. You MUST be at least 16 years

of age and have a valid driver’s license to operate this vehicle.

• No person under the age of 12 may ride as a passenger in this vehicle.

• Never permit a guest to operate this vehicle unless the guest has read this

manual and all product labels.

• Always keep hands, feet, and all other body parts inside the vehicle at all

times.

• Always wear the proper clothing when operating or riding in this vehicle. All

riders should wear substantial footwear, long pants, and a close-fitting shirt.

A hard hat or helmet and approved eye protection are recommended when

appropriate for riding or working conditions.

• Never operate this vehicle under the influence of drugs or alcohol, as these

conditions impair judgement and the operator’s ability to react.

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.

WARNING

WARNING indicates a hazardous situation which, if not avoided, COULD result

in death or serious injury.

CAUTION

CAUTION indicates a hazardous situation which, if not avoided, COULD result

in minor to moderate injury.

NOTICE

NOTICE provides key information by clarifying instructions.

IMPORTANT

IMPORTANT provides key reminders during disassembly, assembly, and

inspection of components.

The Prohibition Safety Sign indicates an action NOT to take in

order to avoid a hazard.

The Mandatory Action Sign indicates an action that NEEDS to

be taken to avoid a hazard.

INTRODUCTION

VEHICLE IDENTIFICATION NUMBERS

Record your vehicle's identification numbers in the spaces provided. The engine

serial number is located on the side of the engine, below the injection pump.

All keys have the number 4083. Remove the spare key and store it in a safe

place. Additional pre-cut keys for your vehicle can be ordered.

Vehicle Model Number

Vehicle Identification Number (VIN)

Engine Serial Number w

Key Number 4083

INTRODUCTION

SAFETY

PERSONAL PROTECTIVE EQUIPMENT

Always wear the proper clothing when operating or riding in this vehicle. All

riders should wear substantial footwear, long pants and a close-fitting shirt. A

hard hat or helmet and approved eye protection are recommended when

appropriate for working or riding conditions. POLARIS recommends wearing

approved eye protection bearing markings such as VESC 8, V-8, Z87.1 or CE.

Never operate or ride in this vehicle while barefoot or while wearing sandals or

tennis shoes.

Workplace safety regulations may require the use of safety glasses, safety

shoes and a hard hat or helmet. Familiarize yourself with local requirements, be

prepared for operating conditions and wear the appropriate safety gear.

RIDER COMFORT

Under certain operating conditions, heat generated by the engine and exhaust

system can elevate temperatures in the driver and passenger cab area. The

condition occurs most frequently when a vehicle is being operated in high

ambient temperatures at low speeds and/or high load conditions for an extended

period of time. The use of certain windshield, roof and/or cab systems may

contribute to this condition by restricting airflow. Any discomfort due to heat

buildup in this area can be minimized by wearing proper riding apparel and by

varying speeds to increase airflow.

SAFETY

SAFETY LABELS AND LOCATIONS

Warning labels have been placed on the vehicle for your protection. Read and

follow the instructions of the labels on the vehicle carefully. If any of the labels

depicted in this manual differ from the labels on your vehicle, always read and

follow the instructions of the labels on the .vehicle

If an informational or graphic label becomes illegible or comes off, contact your

POLARIS dealer to purchase a replacement. Replacement labels aresafety

provided by POLARIS at no charge. The part number is printed on the label.

The seat belt/drive responsibly warning label , the proper use warning label, and

the payload warning are located on the front ROPS, above the driver’s head q.

SEAT BELT / DRIVE RESPONSIBLY WARNING

WARNING

Part Number: 7300410

IMPROPER VEHICLE USE CAN RESULT IN SERIOUS INJURY OR DEATH

NEVER OPERATE:

• At speeds too fast for your skills or the conditions.

• After or while using Alcohol or Drugs.

• Across slopes (Avoid side hilling).

• On public roads. This vehicle is for off-highway use only. Driving on public

roads could be a violation of law and may be hazardous.

SAFETY

• With more passengers than described in the Operation & Maintenance

Manual, with children under the age of 12, and passengers who cannot

comfortably reach the floor and hand holds with back against the seat.

• With unapproved accessories - they may seriously affect stability.

LOCATE AND READ OPERATION & MAINTENANCE MANUAL. FOLLOW

ALL INSTRUCTIONS AND WARNINGS.

ALWAYS:

• Wear head protection - such as a hard hat or helmet - as appropriate for

conditions and usage. Consult manual for more information.

• Wear your seatbelt. Vehicle rollover could cause serious injury or death.

• Wear eye protection and keep hands and feet in vehicle at all times.

• Reduce speed and use extra caution when carrying passengers.

• Avoid sharp turns or turns while applying heavy throttle.

• Operate slowly in reverse - avoid sharp turns or sudden braking.

• Make sure passengers read and understand all warning labels.

• Watch for branches or other hazards that could enter vehicle.

• Use caution while operating vehicle on private paved surfaces. Pavement can

alter handling and may cause loss of control.

Be Sure Riders Pay Attention and Plan Ahead

If you think or feel the vehicle may tip or roll, reduce your risk to injury:

• Keep a firm grip on the steering wheel or handholds and brace yourself.

• Do not put any part of your body outside of the vehicle for any reason.

Rollovers have caused severe injuries and death, even on flat, open areas.

SAFETY

PROPER USE WARNING (2-SEAT)

WARNING

Part Number: 7300098

Require Proper Use of Your Vehicle

Do your part to prevent injuries:

• Do not allow careless or reckless driving.

• Make sure operators are 16 or older with a valid driver’s license.

• Do not let people drive or ride after using alcohol or drugs.

• Do not allow operation on public roads (unless designated for off-highway

vehicle access) - collisions with cars and trucks can occur.

• Do not exceed seating capacity: 2 occupants.

PROPER USE WARNING (4-SEAT)

WARNING

Part Number: 7300099

Require Proper Use of Your Vehicle

Do your part to prevent injuries:

• Do not allow careless or reckless driving.

• Make sure operators are 16 or older with a valid driver’s license.

• Do not let people drive or ride after using alcohol or drugs.

• Do not allow operation on public roads (unless designated for off-highway

vehicle access) - collisions with cars and trucks can occur.

• Do not exceed seating capacity: 4 occupants.

SAFETY

PAYLOAD WARNING

WARNING

Part Number: 7300213

WARNING

MODEL NEVER EXCEED IF TOTAL PAYLOAD

EXCEEDS

2000D 25 mph (40 kph) 860 lbs. (376 kg)

2000G 25 mph (40 kph) 860 lbs. (376 kg)

4000D 25 mph (40 kph) 1250 lbs. (567 kg)

4000G 25 mph (40 kph) 1250 lbs. (567 kg)

FUEL TRANSPORT WARNING

The fuel transport warning label qis located in the cargo box.

WARNING

Part Number: 7186122

NEVER carry fuel or other flammable liquids on this vehicle.

Failure to follow this instruction could lead to serious burn injuries or death.

SAFETY

LOAD/PASSENGER/TIRE PRESSURE WARNING

The load/passenger/tire pressure warning label is located next to the fuel

transport warning label in the cargo box.

WARNING

Part Number: 7300252

WARNING

FALLING OFF CARGO BOX CAN CAUSE SERIOUS INJURY OR DEATH

• Never carry riders in cargo box.

OVERLOADING OR IMPROPER TIRE PRESSURE CAN CAUSE TIPPING

OR LOSS OF CONTROL RESULTING IN SERIOUS INJURY OR DEATH

• Never exceed load capacities.

• Reduce speed and allow greater distance for braking when carrying cargo.

• Carrying tall, off-center, or unsecured loads will increase your risk of losing

control. Center and secure loads as low as possible in box.

• Reduce speed and cargo on rough or hilly terrain.

• Check for proper tire pressures.

MODEL

NUMBER 2000D 4000D 2000G 4000G

MAXIMUM

CARGO

BOX LOAD

1250 lbs.

(566 kg)

1250 lbs.

(566 kg)

1250 lbs.

(566 kg)

1250 lbs.

(566 kg)

TIRE

PRESSURE

IN PSI (KPa)

FRONT 24

(165)

REAR 24

(165)

FRONT 24

(165)

REAR 24

(165)

FRONT 5

(34)

REAR 20

(138)

FRONT 10

(69)

REAR 20

(138)

SAFETY

MODEL

NUMBER 2000D 4000D 2000G 4000G

VEHICLE

RATED

CAPACITY

INCLUDES

WEIGHT OF

OPERATOR,

PASSEN-

GER,

CARGO,

AND

ACCESSO-

RIES.

1900 lbs.

(861 kg)

2075 lbs.

(941 kg)

1900 lbs.

(861 kg)

2075 lbs.

(941 kg)

Read Operation & Maintenance Manual for more detailed loading information.

SAFETY

CLUTCH COVER WARNING

The clutch cover warning qis located on the clutch cover.

WARNING

Part Number: 7182350

Improper service or maintenance of this CVT 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 an authorized service dealer.

SAFETY

SHIFT CAUTION

The shift caution qis located above the ignition switch.

CAUTION

Part Number: 7300087

To avoid transmission damage, shift only when vehicle is stationary and at idle.

When vehicle is stopped, place gear selector in PARK.

SAFETY

PULLEY WARNING

The pulley warning qis located on the rear frame.

WARNING

Part Number: 7182156

Moving parts present. Keep hands away from moving parts to prevent injury.

TRAILER/HITCH CAPACITY

The trailer/hitch capacity label is located on the rear hitch bracket.

CAUTION

Part Number: 7300095

CAUTION:

HOT SURFACE. DO NOT TOUCH.

TRAILER MAX. WEIGHT: 2500 LBS. (1134 kg)

HITCH MAX. VERTICAL WEIGHT: 250 LBS. (114 kg)

SAFETY

OPERATOR SAFETY

WARNING

Serious injury or death can result if you do not follow these instructions and

procedures, which are outlined in further detail within your owner's manual.

• Read this entire manual and all labels carefully. Follow the operating

procedures described.

• Never allow anyone under the age of 16 to operate this vehicle and never

allow anyone without a valid driver's license to operate this vehicle.

• Do not carry a passenger until you have at least two hours of driving

experience with this vehicle.

• No person under the age of 12 may ride as a passenger in this vehicle.

• Always keep hands and feet inside the vehicle at all times. Always keep both

hands on the steering wheel (driver) and both feet on the floorboards of the

vehicle during operation.

• Never permit a guest to operate this vehicle unless the guest has read this

manual and all product labels.

• Always make sure the seat belts are secured for operator and passenger

before operating.

• Never exceed the stated load capacity for this vehicle. Cargo should be

properly distributed and securely attached. Reduce speed and follow the

instructions in this manual for hauling cargo or pulling a trailer. Allow a greater

distance for braking.

• Always be sure there are no obstacles or people behind your vehicle when

operating in reverse. When it's safe to proceed in reverse, move slowly. Avoid

turning at sharp angles in reverse.

• Always use the proper size and type of tires specified in this manual. Always

maintain proper tire pressure as specified on safety labels.

• Never modify this vehicle through improper installation or use of non-

POLARIS-approved accessories.

• Always set the park brake and remove the key when leaving the vehicle

unattended.

• Never consume alcohol or drugs before or while operating this vehicle.

• Never operate at excessive speeds. Always operate at a speed that's

appropriate for the traffic, the visibility and operating conditions, your skills

and your passengers’ skills.

• Always inspect the vehicle before each use to make sure it's in safe operating

condition. Always follow the inspection procedures described in this manual.

• Always travel slowly and use extra caution when operating on unfamiliar

terrain. Be alert to changing terrain.

• Always follow proper procedures for turning. Make turns slowly, especially

when the ground is wet, greasy, bumpy or sloping. Never turn the steering

wheel abruptly when driving at high speed.

SAFETY

• Always have this vehicle checked by an authorized POLARIS dealer if it has

been involved in an accident.

• Always be alert for obstacles when operating this vehicle. Never attempt to

operate over obstacles.

• Never operate this vehicle on steep hills.

• Never operate on excessively rough, slippery or loose terrain.

• Always be careful of skidding or sliding. On slippery surfaces such as ice,

travel slowly and exercise caution to reduce the chance of skidding or sliding

out of control.

• Always be sure there are no obstacles or people behind your vehicle when

operating in reverse. When it's safe to proceed in reverse, move slowly. Avoid

turning at sharp angles in reverse.

• Always stop the engine before refueling. Remove flammable material

containers from the box before filling them with fuel. Make sure the refueling

area is well ventilated and free of any source of flame or sparks.

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. See the Operation

chapter of this owner’s manual for proper operating procedures.

OPERATING WITHOUT INSTRUCTION

Operating this vehicle without proper instruction

increases the risk of an accident. The operator must

understand how to operate the vehicle properly in

different situations and on different types of terrain. All

operators must read and understand the Owner's

Manual and all warning and instruction labels before

operating the vehicle.

AGE RESTRICTIONS

This vehicle is an ADULT VEHICLE ONLY. Operation

is prohibited for anyone under 16 years of age or

anyone without a valid driver’s license.

The operator must be tall enough to sit with back

against the seat, both feet flat on the floor and both

hands on the steering wheel (if equipped) or

handlebars.

SAFETY

USING ALCOHOL OR DRUGS

WARNING

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. Always perform the Pre-

Ride Inspection outlined in the Operation chapter before each use of your

vehicle to make sure it's in safe operating condition. Always follow the

inspection and maintenance procedures and schedules described in this

owner’s manual. See the Periodic Maintenance section of the Maintenance

chapter.

SEAT BELTS

WARNING

Riding in this vehicle without wearing the seat belt increases the risk of serious

injury in the event of rollover, loss of control, other accident or sudden stop.

Seat belts may reduce the severity of injury in these circumstances. The

operator and all passengers MUST wear their seat belt at all times.

IMPROPER TIRE MAINTENANCE

WARNING

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.

SAFETY

OPERATING WITH A LOAD ON THE VEHICLE

The weight of the cargo, operator, and passengers impacts vehicle operation

and stability. For your safety and the safety of others, carefully consider how

your vehicle is loaded and how to safely operate the vehicle. Follow the

instructions in this manual for loading, tire pressure, gear selection and speed.

• The vehicle’s maximum weightDo not exceed vehicle weight capacities.

capacity is listed in the specifications section of this manual and on a label on

the vehicle. When determining the weight you are adding to the vehicle,

include the weight of the operator, passengers, accessories, loads in the rack

or box and the load on the trailer tongue. The combined weight of these items

must not exceed the maximum weight capacity.

• The recommended tire pressures are listed in the specifications section of this

manual and on a label on the vehicle.

Always follow these guidelines:

UNDER ANY OF THESE CONDITIONS: DO ALL OF THESE STEPS:

Operator and/or cargo exceeds half the

maximum weight capacity

1. Slow down.

2. Verify tire pressure.

3. Use extra caution when operating.

Operating in rough terrain

Operating over obstacles

Climbing an incline

Towing

OPERATING AT EXCESSIVE SPEEDS

CAUTION

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.

JUMPS AND STUNTS

CAUTION

Exhibition driving increases the risk of an accident or rollover. DO NOT do

power slides, “donuts”, jumps or other driving stunts. Avoid exhibition driving.

SAFETY

TURNING IMPROPERLY

CAUTION

Turning improperly could cause loss of traction, loss of control, accident or

rollover. Always follow proper procedures for turning as described in this

owner’s manual.

Avoid sharp turns. Never turn while applying heavy throttle. Never make abrupt

steering maneuvers. Practice turning at slow speeds before attempting to turn at

faster speeds.

IMPROPER HILL CLIMBING

CAUTION

Improper hill climbing could cause loss of control or rollover. Use extreme

caution when operating on hills. Always follow proper procedures for hill

climbing as described in this owner's manual.

DESCENDING HILLS IMPROPERLY

CAUTION

Improperly descending a hill could cause loss of control or rollover. Always

follow proper procedures for traveling down hills as described in this owner’s

manual.

CROSSING HILLSIDES

CAUTION

Driving on a sidehill is not recommended. Improper procedure could cause

loss of control or rollover. Avoid crossing the side of any hill unless absolutely

necessary. If crossing a hillside is unavoidable, always follow proper

procedures as described in this owner's manual.

SAFETY

STALLING WHILE CLIMBING A HILL

CAUTION

Stalling or rolling backwards while climbing a hill could cause a rollover.

Maintain a steady speed when climbing a hill.

If you lose all forward speed:

Apply the brakes gradually until the vehicle is fully stopped. Place the

transmission in reverse and slowly allow the vehicle to roll straight downhill while

applying light brake pressure to control speed.

If you begin rolling downhill:

Never apply engine power. Apply the brakes gradually until the vehicle is fully

stopped. Place the transmission in reverse and slowly allow the vehicle to roll

straight downhill while applying light brake pressure to control speed.

OPERATING IN UNFAMILIAR TERRAIN

CAUTION

Failure to use extra caution when operating on unfamiliar terrain could result in

an accident or rollover.

CAUTION

Unfamiliar terrain may contain hidden rocks, bumps, or holes that could cause

loss of control or rollover.

Travel slowly and use extra caution when operating on unfamiliar terrain. Always

be alert to changing terrain conditions.

OPERATING IMPROPERLY IN REVERSE

CAUTION

Improperly operating in reverse could result in a collision with an obstacle or

person. Always follow proper operating procedures as outlined in this manual.

Before shifting into reverse gear, always check for obstacles or people behind

the vehicle. When it's safe to proceed, back slowly.

SAFETY

SKIDDING OR SLIDING

CAUTION

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.

CAUTION

Skidding or sliding due to loss of traction can cause loss of control or rollover (if

tires regain traction unexpectedly). Always follow proper procedures for

operating on slippery surfaces as described in this owner's manual.

OPERATING OVER OBSTACLES

CAUTION

Improperly operating over obstacles could cause loss of control or rollover.

Before operating in a new area, check for obstacles. Avoid operating over

large obstacles such as large rocks and fallen trees. Always follow the proper

procedures outlined in this manual when operating over obstacles.

OPERATING THROUGH WATER

CAUTION

Operating through deep or fast-flowing water can cause loss of traction, loss of

control, rollover or accident. Never operate in fast-flowing water or in water that

exceeds the floor level of the vehicle.

Always follow proper procedures for operating in water as described in this

owner’s manual.

Wet brakes will have reduced stopping ability. After leaving water, test the

brakes. Apply them lightly several times while driving slowly. The friction will help

dry out the pads.

SAFETY

OPERATING ON FROZEN BODIES OF WATER

WARNING

Serious injury or death can result if the vehicle and/or the operator fall through

the ice. Never operate the vehicle on a frozen body of water unless you have

first verified that the ice is sufficiently thick to support the weight and moving

force of the vehicle, you and your cargo, together with any other vehicles in

your party.

Always check with local authorities and residents to confirm ice conditions and

thickness over your entire route. Vehicle operators assume all risk associated

with ice conditions on frozen bodies of water.

OPERATING A DAMAGED VEHICLE

CAUTION

Operating a damaged vehicle can result in an accident. After any rollover or

other accident, have a qualified service dealer inspect the entire machine for

possible damage, including (but not limited to) seat belts, rollover protection

devices, brakes, throttle, and steering systems.

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.

• Cargo should be properly distributed and securely attached.

• Reduce speed when carrying cargo or pulling a trailer. Allow a greater

distance for braking.

POOR VISIBILITY

CAUTION

Operating this vehicle in darkness or inclement weather could result in a

collision or accident, especially if operating on a road or street. This vehicle is

not equipped with highway-approved lights. Operate this vehicle off-road only.

Use caution and drive at reduced speeds in conditions of reduced visibility

such as fog, rain and darkness. Clean headlights frequently and replace

burned out headlamps promptly.

SAFETY

HOT EXHAUST SYSTEMS

WARNING

Exhaust system components are very hot during and after use of the vehicle.

Hot components can cause burns and fire. Do not touch hot exhaust system

components. Always keep combustible materials away from the exhaust

system.

Use caution when traveling through tall grass, especially dry grass and when

traveling through muddy conditions. Always inspect the underside of the

vehicle and areas near the exhaust system after driving through tall grass,

weeds, brush, other tall ground cover, and muddy conditions. Promptly remove

any grass, debris or foreign matter clinging to the vehicle and pay particular

attention to the exhaust system area.

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.

UNAUTHORIZED USE OF THE VEHICLE

Leaving the keys in the ignition can lead to unauthorized use of the vehicle by

someone under the age of 16, without a drivers license, or without proper

training. This could result in an accident or rollover. Always remove the ignition

key when the vehicle is not in use.

SAFETY

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. This vehicle may

become less stable at speeds higher than those for which it is designed. Loss of

control may occur at higher speeds.

Do not install any non-POLARIS-approved accessory or modify the vehicle for

the purpose of increasing speed or power. Any modifications or installation of

non-POLARIS-approved accessories could create a substantial safety hazard

and increase the risk of bodily injury.

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.

The addition of certain accessories, including (but not limited to) mowers,

blades, tires, sprayers, or large racks, may change the handling characteristics

of the vehicle. Use only POLARIS-approved accessories, and familiarize

yourself with their function and effect on the vehicle.

The addition of certain accessories, including (but not limited to) overhead audio

speakers, may change the forward clearance in the vehicle. Polaris

recommends selecting a helmet that is compatible with the equipment on your

vehicle and provides the greatest amount of forward clearance. Always wear a

helmet that meets or exceeds the specifications in this owner’s manual. Refer to

the Safe Riding Gear section of this owner’s manual for more information. Use

only POLARIS-approved accessories.

FOR MORE INFORMATION ABOUT SAFETY IN THE UNITED STATES call

POLARIS at 1-800-342-3764.

SAFETY

FEATURES AND CONTROLS

COMPONENT LOCATIONS

qConsole

wHeadlights

eRadiator

rFront Bumper / Brush Guard

tMuffler (Spark Arrester)

yReceiver Hitch

uCV Boot / Rear Caliper

iROPS Cab Frame

oCargo Box

aTailgate

sFuel Cap

FEATURES AND CONTROLS

CONSOLE

qCup Holder

wLight Switch

eInstrument Cluster

rIgnition Switch

tGear Selector (Shifter)

yPark Brake

uHorn Switch

iDriver’s Side Auxiliary Outlet

oPassenger Side Auxiliary Outlet

aStorage Compartment

FEATURES AND CONTROLS

AUXILIARY OUTLETS

The auxiliary outlets can be used to

power standard 12V accessories like a

cell phone charger or a power inverter up

to 120 watts. The driver’s side auxiliary

outlet is always on, even when the vehicle

is switched off and the key is removed.

This driver’s side outlet is always on so

that a battery maintainer may be

connected to maintain the battery while

the vehicle is in storage. The passenger

side outlet (and the rear outlet on 4000

models) switches on and off with the

vehicle. These outlets cannot be used to

charge the battery because they

disconnect when the vehicle is off. 4000

models have a third auxiliary outlet on

switched power located in the center

console between the rear seats.

ADJUSTABLE STEERING WHEEL

The steering wheel can be tilted upward

or downward for rider preference. Lift

and hold the adjustment lever qtoward

you while moving the steering wheel

upward or downward. Release the lever

when the steering wheel is at the

desired position.

FEATURES AND CONTROLS

GEAR SELECTOR

Low gear is the primary driving range for the . High gear is intended forPRO XD

use on hard-packed surfaces with light loads. Using high gear for heavy loads,

hilly terrain or in wet, muddy conditions will increase the chance of drive belt

spinning. An alarm will sound if the vehicle detects belt spin. See the Drive Belt

Wear/Spin section on page 173.

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.

NOTICE

Shifting gears with the engine speed above idle or while the vehicle is moving

could cause transmission damage. Always shift when the vehicle is stationary

and the engine is at idle.

TIP

Maintaining shift linkage adjustment is important to assure proper transmission

function. See your dealer if you experience any shifting problems.

USING LOW RANGE

Always shift into low gear for any of the following conditions.

• Operating in rough terrain or over obstacles

• Loading the vehicle onto a trailer

• Towing loads

• Driving frequently at low RPM or at ground speeds below 7 mph (11 km/h)

REVERSE ALERT BEEPER

Putting the vehicle into reverse will automatically activate the reverse alert

beeper.

FEATURES AND CONTROLS

PARK BRAKE LEVER

Always apply the service brakes before engaging or releasing the park brake q.

To help prevent the vehicle from rolling, set the park brake when parking the

vehicle. When the park brake is set and the park brake indicator is illuminated,

an alarm will sound if pressure is put on the throttle pedal.

TIP

This feature will not operate properly if the park brake connector or switch

(under the dash) malfunctions or becomes disconnected, or if the switch has

moved. Check for disconnection, then see your dealer or other qualified

service person promptly if this feature fails to operate properly.

1. To set the park brake, apply the brakes. Pull the park brake lever towards

yourself as far as possible.

2. To release the park brake, apply the brakes. Turn the park brake lever

counterclockwise and push it in as far as possible.

FEATURES AND CONTROLS

SWITCHES

IGNITION SWITCH

The ignition switch is a three-position,

key-operated switch. The key can be

removed from the switch when it is in

the OFF position.

OFF The engine is off. Electrical circuits are off, except for the

driver’s side auxiliary outlet and the Pulse Bar.

ON Vehicle is on. All electrical equipment can be used. When

first keyed on, glow plugs activate for 12 seconds and

then deactivate. The indicator on the gauge displays

when glow plugs are active.

START Turn the key to the START position to engage the starter.

The key returns to the ON position when released.

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. Press the

bottom of the switch to turn off the

headlights.

FEATURES AND CONTROLS

AWD SWITCH (IF EQUIPPED)

The AWD switch has three positions: All

Wheel Drive (AWD), Differential Lock/Two

Wheel Drive (2WD) and Off (1WD/Turf

Mode).

Press the top of the switch to engage All

Wheel Drive (AWD).

Move the switch to the center position to lock

the differential and operate in two wheel drive

(2WD).

Press the bottom of the switch to unlock the

differential and allow the rear drive wheels to

operate independently (1WD). This mode of

operation is well suited to turf driving or when

active traction is not needed.

PULSE BAR

The Pulse Bar qis located under

the hood and can be used to

connect any Pulse Bar accessory to

the vehicle. The Pulse Bar receives

constant and switched power from

the battery, so that accessories may

be powered whether the vehicle is

on or off.

FEATURES AND CONTROLS

FOOT PEDALS

BRAKE PEDAL

Depress the brake pedal qto 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. Turn the ignition switch to the ON position.

2. Apply the brakes. The brake light should come on after about 0.4 in (10 mm)

of pedal travel.

THROTTLE PEDAL

Push the throttle pedal wdown to increase engine speed. Spring pressure

returns the pedal to the rest position when released. Always check that the

throttle pedal returns normally before starting the engine.

SEAT AND STORAGE COMPARTMENTS

The electrical compartment is located under the center rear-most seat. Never

use this area for storage. Storage compartments are located under all other

seats. Remove the storage bin under the right rear-most passenger seat to

access the battery.

Always make sure all seats are properly installed before operating. Push down

firmly on the rear of each seat until the latch pins are fully seated into the

grommets.

FEATURES AND CONTROLS

DRIVER’S SEAT

To access the storage area under the driver’s seat, reach behind the driver’s

seat and pull up on the latch. Roll the bottom of the seat forward toward steering

wheel.

PASSENGER’S SEAT

To access the storage area under the passenger seat, lift up on the front of the

passenger seat and raise it to the upright position.

ELECTRONIC POWER STEERING (EPS) (IF

EQUIPPED)

Electronic power steering engages when the ignition key is turned to the ON

position. EPS remains engaged whether the vehicle is moving or idle.

To conserve battery power, the EPS will shut down 5 minutes after the engine is

stopped if the key remains in the ON position. The EPS warning indicator will

illuminate to indicate the EPS has shut down. 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.

BELT SPIN ALARM

The Belt Spin Alarm will sound if the vehicle senses or detects belt spin (engine

RPM without ground speed). The instrument cluster will also scroll the message

“belt damage occurring”. If the alarm continues to sound frequently, shift to low

gear.

FUEL CAP

The fuel tank filler cap qis located

on the left-hand side of the vehicle

near the driver’s seat. Use only the

recommended diesel fuel.

OCCUPANT PROTECTION STRUCTURE (OPS)

The Occupant Protection Structure (OPS) on this vehicle meets ANSI/OPEI

B71.9 standards. Always have your authorized dealer thoroughly inspect the

OPS if it ever becomes damaged in any way.

No device can assure occupant protection in the event of a rollover. Always

follow all safe operating practices outlined in this manual to avoid vehicle

rollover.

FEATURES AND CONTROLS

WARNING

Vehicle rollover could cause serious injury or death. Always avoid operating in

a manner that could result in vehicle rollover.

HOOD LATCHES

To remove the hood, rotate the hood

latches q1/4-turn and lift the hood

away from the vehicle.

TRAILER HITCH BRACKET

This vehicle is equipped with a receiver hitch bracket for a trailer hitch. Trailer

towing equipment is not supplied with this vehicle.

To avoid injury and property damage, always heed the warnings and towing

capacities.

FEATURES AND CONTROLS

SEAT BELTS

This POLARIS vehicle is equipped with three-point lap and diagonal seat belts

on all seats. Always make sure the seat belts are secured for all riders before

operating.

WARNING

Falling from a moving vehicle could result in serious injury or death. Always

fasten your seat belt securely before operating or riding.

To wear the seat belt properly, follow this procedure:

1. For 3-point belts with D loops w, pull

the seat belt latch downward and

across your chest toward the buckle

qat the inner edge of the seat. The

belt should fit snugly across your

hips and diagonally across your

chest. Make sure the belt is not

twisted.

2. Push the latch plate into the buckle

until it clicks.

3. Release the strap, it will self-tighten.

4. To release the seat belt, press the

square red button in the buckle’s

center.

SEAT BELT INSPECTION

Inspect all seat belts for proper operation before each use of the vehicle.

1. Push the latch plate into the buckle until it clicks. The latch plate must slide

smoothly into the buckle. A click indicates that it's securely latched.

2. Push the red release latch in the middle of the buckle to make sure it

releases freely.

3. Pull each seat belt completely out and inspect the full length for any damage,

including cuts, wear, fraying or stiffness. If any damage is found, or if the seat

belt does not operate properly, have the seat belt system checked and/or

replaced by an authorized POLARIS dealer.

4. To clean dirt or debris from the seat belts, sponge the straps with mild soap

and water. Do not use bleach, dye or household detergents.

FEATURES AND CONTROLS

INSTRUMENT CLUSTER

OVERVIEW

NOTICE

The use of a high pressure washer may damage the instrument cluster. Wash

the vehicle by hand or with a garden hose using mild soap. Do not use alcohol

to clean the instrument cluster. Do not allow insect sprays to contact the lens.

Immediately clean off any gasoline that splashes on the instrument cluster.

qGear Indicator

H = High Gear

L = Low Gear

N = Neutral

R = Reverse Gear

P = Park

– = Gear Signal Error (or shifter between gears)

wDisplay Area 2

This area displays odometer, trip meter, trip meter 2, voltage, engine

temperature, engine hour meter, programmable service hour interval,

ground speed, or engine RPM.

eDisplay Area 1 This area displays engine RPM, ground speed, or coolant temperature.

rFuel Gauge

The segments of the fuel gauge show the level of fuel in the fuel tank.

When the last segment clears, a low fuel warning is activated. All

segments including the fuel icon will flash. Refuel immediately.

tService Indicator

A flashing wrench symbol alerts the operator that the preset service

interval has been reached. Your POLARIS dealer can provide scheduled

maintenance. See page 57 for more information.

FEATURES AND CONTROLS

yClock The clock displays time in a 12-hour or 24-hour format.

uDifferential Lock/

Turf Mode Indicator Not used on this vehicle as the vehicle is full time AWD.

INDICATOR LAMPS

qCheck

Engine

This lamp illuminates when the ECM detects a

Diagnostic Trouble Code in the engine

management system. Do not operate the

vehicle if this warning appears. Serious engine

damage could result. Your authorized POLARIS

dealer can assist. This lamp will also illuminate

if the vehicle is keyed on but not started; it will

turn off once the vehicle is started.

wEPS Warning

(if equipped)

This lamp illuminates to indicate that EPS has

shut down. EPS shuts down automatically 5

minutes after the engine is turned off if the key

remains in the ON position. Turn the key off and

on to reset the unit. If the light remains on after

starting the engine, the EPS system is

inoperative. Your POLARIS dealer can assist.

eEngine Hot

This lamp illuminates to indicate an overheated

engine. If the indicator flashes, a severe

overheating condition exists and the engine will

shut down automatically. The vehicle will not

start again until the engine has sufficiently

cooled down. Whenever this lamp illuminates,

FEATURES AND CONTROLS

the engine load should be reduced in any way

possible to avoid overheating and shutting down

the engine.

rLow Oil

Pressure

This lamp illuminates if engine oil pressure

drops below safe operating pressure. If this

lamp illuminates while the engine is running,

turn the engine off as soon as safely possible

and check the oil level. If the oil level is correct

and the lamp remains on after the engine is

restarted, turn the engine off immediately.

tSeat Belt

This lamp flashes for several seconds when the

key is turned to the ON position. The lamp will

keep flashing as long as riders’ seat belts are

not connected.

yHigh Beam This lamp illuminates when the headlamp

switch is set to high beam.

uPark Brake

Indicator

This lamp illuminates when the park brake is

active.

iGlow Plug

Indicator

This lamp illuminates when the glow plugs are

active.

FEATURES AND CONTROLS

DISPLAY AREA 1

Pressing the MODE button will change the information displayed in Area 1q.

Speed Engine Temperature

RPM Ambient Temperature (Optional)

FEATURES AND CONTROLS

DISPLAY AREA 2

Toggle the Up/Down buttons to change the information displayed in Area 2w.

Odometer Engine Temperature

Trip 1 Ambient Temperature (Optional)

FEATURES AND CONTROLS

Trip 2 RPM

Voltage Speed

Engine Hours Service Hours

FEATURES AND CONTROLS

OPTIONS MENU

Press and hold the MODE button to enter the Options Menu.

OPTIONS MENU NOTES

Diagnostic Codes Only displays if fault codes are

present or stored

Units - Distance Select MPH or KPH

Units - Temp Select between °F and °C

Clock Select between 12H or 24H, and set

time

Backlight Color Select between Blue or Red

Backlight Level Set backlight brightness level

Service Hours View/Set Service hours

Exit Menu Exit

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.

Reference the image shown above:

qPress the MODE button.

wToggle the Up/Down Buttons to change the units (MPH or KPH)

eWith the correct unit displayed, Press the mode button which will set

the unit and return to the Options Menu.

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.

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:

qPress the MODE button.

wToggle the Up/Down Buttons to change the units (°F or °C)

eWith the correct unit displayed, Press the mode button which will set

the unit and return to the Options Menu.

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.

FEATURES AND CONTROLS

CLOCK

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.

FEATURES AND CONTROLS

2. Select “Clock” from the Options Menu by pressing the MODE button.

Reference the image shown above:

qPress the MODE button.

wToggle the Up/Down Buttons to change the units (12H or 24H)

eWith the correct unit displayed, Press the mode button which will set

the unit.

rToggle the Up/Down Buttons to change the units (Cycles Hours)

tWith the correct unit displayed, Press the mode button which will set

the unit.

yToggle the Up/Down Buttons to change the units (Cycles 10s of

Minutes)

uWith the correct unit displayed, Press the mode button which will set

the unit.

iToggle the Up/Down Buttons to change the units (Cycles 1s of

Minutes)

oWith the correct unit displayed, Press the mode button which will set

the unit and return to the Options Menu.

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.

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.

Reference the image shown above:

qPress the MODE button.

wToggle the Up/Down Buttons to change the units (Blue or Red)

eWith the correct unit displayed, Press the mode button which will set

the unit and return to the Options Menu.

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.

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.

Reference the image shown above:

qPress the MODE button.

wToggle the Up/Down Buttons to change the units (Increase or De-

crease Level)

eWith the correct unit displayed, Press the mode button which will set

the unit and return to the Options Menu.

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.

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:

qPress the MODE button.

wToggle the Up/Down Buttons to change the units (0, 5, 10 - 95, 100)

eWith the correct unit displayed, press the MODE button, which will set

the unit and return you to the Options Menu.

NOTICE

To reset service hours after they have counted down to "0.0", reselect the

existing setpoint or select a new service hour value.

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.

FEATURES AND CONTROLS

DIAGNOSTIC CODE

NOTICE

Diagnostic Code Screen will show available MIL that has come on during that

ignition cycle.

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 “Diagnostic Codes” from the Options Menu by pressing the MODE

button.

Toggle the Up/Down Buttons to cycle through Code(s).

NOTICE

This option will only be available if a fault code was set or is active during the

current ignition key 'on' cycle. Turning off the ignition will clear any save fault

codes from the gauge.

Reference the image shown above:

qArea A will Display FMI (XX)

wArea B will Display SPN (XXXXXX)

eClock Area will Display Count (XXX)

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.

FEATURES AND CONTROLS

DIAGNOSTIC DISPLAY CODE DEFINITIONS

DIAGNOSTIC CODES

COMPONENT CONDITION SPN FMI

Low oil pressure

switch fault

CAN message 65390

Timeout error 100 11

Current below normal

or open circuit 100 5

Engine Temperature

Sensor

Voltage above normal,

or shorted to high

source

110 3

Voltage above normal,

or shorted to high

source

110 4

System Power

(Battery Potential/

Power Input)

Data valid but below

normal operational

range - most severe

level

168 1

Voltage above normal,

or shorted to high

source

168 3

Voltage below normal,

or shorted to low

source

168 4

Gear Sensor Signal Voltage below normal,

or shorted to low

source

523 4

Rear Differential

Output

Voltage above normal,

or shorted to high

source

746 3

Voltage below normal,

or shorted to low

source

746 4

Current below normal

or open circuit 746 5

Fan Relay Driver Ckt. Voltage above normal,

or shorted to high

source

1071 3

Voltage below normal,

or shorted to low

source

1071 4

Current below normal

or open circuit 1071 5

FEATURES AND CONTROLS

DIAGNOSTIC CODES

COMPONENT CONDITION SPN FMI

Fuel Pump Driver Ckt. Voltage above normal,

or shorted to high

source

1347 3

Voltage below normal,

or shorted to low

source

1347 4

Current below normal

or open circuit 1347 5

ECU Output Supply

Voltage 1

Voltage above normal,

or shorted to high

source

3597 3

Voltage below normal,

or shorted to low

source

3597 4

ECU Output Supply

Voltage 3

Voltage above normal,

or shorted to high

source

3598 3

Voltage below normal,

or shorted to low

source

3598 4

All Wheel Drive

Control Circuit

Voltage above normal,

or shorted to high

source

520207 3

Voltage below normal,

or shorted to low

source

520207 4

Current below normal

or open circuit 520207 5

Brake failure lamp

faults

Voltage above normal,

or shorted to high

source

520214 3

Voltage below normal,

or shorted to low

source

520214 4

Current below normal

or open circuit 520214 5

Glow Plug Relay

Driver Circuit

Voltage above normal,

or shorted to high

source

520272 3

Voltage below normal,

or shorted to low

source

520272 4

FEATURES AND CONTROLS

DIAGNOSTIC CODES

COMPONENT CONDITION SPN FMI

Current below normal

or open circuit 520272 5

Brake switch (1 or 2

indeterminable)

Data erratic,

intermittent or

incorrect

520285 2

Engine Oil Pressure

Sensor

Data valid but below

normal operating

range - least severe

level

524076 17

FEATURES AND CONTROLS

OPERATION

IMPORTANT INFORMATION

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.

VEHICLE BREAK-IN PERIOD

The break-in period for your new vehicle is the first 50 hours of operation. No

single action on your part is as important as a proper break-in period. Careful

treatment of a new engine will result in more efficient performance and longer

life for the engine. Perform the following procedures carefully.

NOTICE

Excessive heat build-up during the first 3 hours of operation will damage close-

fitted engine parts and drive components. Do not operate at full throttle or high

speeds during the first 3 hours of use.

ENGINE AND DRIVETRAIN BREAK-IN

1. Fill the fuel tank with clean, fresh fuel.

2. Check the oil level. Add the recommended oil as needed to maintain the oil

level in the safe operating range.

3. Complete the New Operator Driving Procedures.

4. Avoid aggressive use of the brakes.

5. Vary throttle positions. Do not operate at sustained idle.

6. Pull only light loads.

7. Perform regular checks on fluid levels, controls and areas outlined on the

daily pre-ride inspection checklist.

8. During the break-in period, change both the oil and the filter at 50 hours or

one month, and every 200 hours thereafter.

9. Check fluid levels of transmission and all gearcases after the first 50 hours of

operation and every 200 hours thereafter.

OPERATION

BRAKE SYSTEM BREAK-IN

Apply only moderate braking force for the first 50 stops. Aggressive or overly

forceful braking when the brake system is new could damage brake pads and

rotors.

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.

If a belt fails, always clean any debris from the PVT intake and outlet duct and

from the clutch and engine compartments when replacing the belt.

SAFE OPERATION PRACTICES

1. Do not allow anyone under 16 years of age or without a valid driver’s license

to operate this vehicle.

2. Engine exhaust fumes are poisonous. Never start the engine or let it run in

an enclosed area.

3. Never operate with accessories not approved by POLARIS for use on this

vehicle.

4. Use caution and drive at reduced speeds in conditions of reduced visibility

such as fog, rain and darkness. Clean headlights frequently and replace

burned out headlamps promptly.

5. Always operate at a speed that's appropriate for the terrain, the visibility and

operating conditions and your skills and experience. Never operate at

excessive speeds. Never attempt wheelies, jumps, or other stunts. Keep

both hands on the steering wheel or handlebars during operation.

6. Never consume alcohol or drugs before or while operating this vehicle.

7. Always use the size and type of tires specified for your vehicle. Always

maintain proper tire pressure.

8. Never operate a damaged vehicle. After any rollover or accident, have a

qualified service dealer inspect the entire machine for possible damage.

9. Never operate the vehicle on a frozen body of water unless you have first

verified that the ice is sufficiently thick to support the weight and moving force

of the vehicle, you and your cargo, together with any other vehicles in your

party.

10. Do not touch hot exhaust system components. Always keep combustible

materials away from the exhaust system.

11. Always remove the ignition key when the vehicle is not in use to prevent

unauthorized use.

OPERATION

PRE-RIDE INSPECTION

WARNING

Failure to inspect and verify that the vehicle is in safe operating condition

before operating increases the risk of an accident. Always inspect the vehicle

before each use to make sure it's in safe operating condition.

ITEM REMARKS PAGE

Air Filter Inspect air filter, ensure it is properly installed;

ensure air box cover is secured and fastened.

Note: Air filter removal is not needed for visual

inspection.

page 132

Steering System Check for tightness/freeplay in the steering

wheel when turned lock to lock

page 148

Front / Rear Suspension Visually inspect for damages to the control arms

/ trailing arms / bushings; check for leaking

shocks

Tires Check for proper air pressure in all tires; visually

inspect for damage; verify there is adequate

tread depth

page 151

Wheels / Lug Nuts Ensure rim is not cracked or bent; verify proper

lug torque

page 152

Headlights / Taillights Ensure all lights are operational; adjust

headlight aim, as needed

page 154

Brake System Check brake fluid level is between MIN and

MAX; ensure brake pedal is not soft when

pushed; inspect for leaks

page 146

Frame / Body Fasteners Visually inspect for loose body / frame fasteners -

Engine Oil Level Verify oil level is in the SAFE range on the

dipstick

page 109

Throttle Inspect for proper operation and smooth travel page 141

Seat Belts Check length of belt for damage, check latches

for proper operation

page 43

Coolant Level Verify coolant level is filled to the FULL COLD

mark on coolant reservoir (if engine is cold);

inspect hoses and radiator for leaks

page 121

Parking Brake Inspect operation page 37

Chassis / Engine Bay /

Exhaust

Remove grass, leaves, foreign matter, and other

flammable material or debris, especially near

the exhaust system.

OPERATION

FUEL RECOMMENDATIONS

NOTICE

For the best engine performance, to prevent engine damage and to comply

with EPA/CARB warranty requirements, use ONLY the recommended diesel

fuels. Use only CLEAN diesel fuel.

POLARIS recommends the following diesel fuels for use in this vehicle:

• Ultra Low Sulfur #2

• #1 Diesel Fuel containing no more than 20% bio-diesel

For more information about recommended diesel fuels and the consequences of

using bio-diesel fuel exceeding 20% bio- diesel, see Additional Technical Fuel

Requirements below.

Diesel fuel should comply with the following world-wide specifications.

DIESEL FUEL SPECIFICATION LOCATION

ASTM D975

No. 1D S15, S500

No. 2D S15, S500

USA

EN590:96 European Union

ISO 8217 DMX International

BS 2869-A1 or A2 United Kingdom

JIS K2204 Grade No. 2 Japan

KSM-2610 Korea

GB252 China

OPERATION

ADDITIONAL TECHNICAL FUEL REQUIREMENTS

• The fuel cetane number should be equal to 45 or higher.

• The sulfur content must not exceed 0.5% by volume. Less than 0.5% is

preferred. Especially in the U.S.A. and Canada, Ultra Low Sulfur fuel should

be used.

• Bio-Diesel fuels.

• NEVER mix kerosene, used engine oil or residual fuels with diesel fuel.

• Water and sediment in the fuel should not exceed 0.05% by volume.

• Keep the fuel tank and fuel-handling equipment clean at all times.

• Poor quality fuel can reduce engine performance and/or cause engine

damage.

• Fuel additives are not recommended. Some fuel additives may cause poor

engine performance.

• Ash content must not exceed 0.01% by volume.

• Carbon residue content must not exceed 0.35% by volume. Less than 0.1% is

preferred.

• Total aromatics content should not exceed 35% by volume. Less than 30% is

preferred.

• PAH (polycyclic aromatic hydrocarbons) content should be below 10% by

volume.

• Metal content of Na, Mg, Si and Al should be equal to or lower than 1 mass

ppm (test analysis method JPI-5S-44-95).

• Lubricity: Wear mark of WS1.4 should be Max. 460μm (0.018 in.) at HFRR

test.

OPERATION

BIO-DIESEL FUELS

In Europe and in the United States, as well as some other countries, non-mineral

oil based fuel resources such as RME (Rapeseed Methyl Ester) and SOME

(Soybean Methyl Ester), collectively known as FAME (Fatty Acid Methyl Esters),

are being used as extenders for mineral oil derived diesel fuels.

These B20 diesel fuels must meet certain requirements:

1. The bio-fuels must meet the minimum specifications for the country in which

they are used.

• In Europe, bio-diesel fuels must comply with the European Standard

EN14214.

• In the United States, bio-diesel fuels must comply with the American

Standard ASTMD-6751.2.

2. Bio-fuels should be purchased only from recognized and authorized diesel

fuel suppliers.

Precautions and concerns regarding the use of bio-fuels:

1. Free methanol in FAME may result in corrosion of aluminum and zinc FIE

components.

2. Free water in FAME may result in plugging of fuel filters and increased

bacterial growth.

3. High viscosity at low temperatures may result in fuel delivery problems,

injection pump seizures and poor injection nozzle spray atomization.

4. FAME may have adverse effects on some elastomers (seal materials) and

may result in fuel leakage and dilution of the engine lubricating oil.

5. Even bio-diesel fuels that comply with a suitable standard as delivered will

require additional care and attention to maintain the quality of the fuel in the

equipment or other fuel tanks. It is important to maintain a supply of clean,

fresh fuel. Regular flushing of the fuel system and/or fuel storage containers

may be necessary.

6. The use of bio-diesel fuels that do not comply with the standards as agreed

to by the diesel engine manufacturers and the diesel fuel injection equipment

manufacturers, or bio-diesel fuels that have degraded as per the precautions

and concerns above, may affect the warranty coverage of your engine.

B21 To B100 Bio-diesel Fuel Blend Usage

B21 to B100 bio-diesel is not approved for this POLARIS application.

Approved Engines

Only the Kubota® engine series listed below may operate with bio-diesel fuel

concentrations up to B20 for POLARIS applications.

OPERATION

NOTICE

Do not exceed bio-diesel fuel blend B20 for this POLARIS application.

• Kubota® 902D

Approved Fuel

NOTICE

Raw pressed vegetable oils are not considered bio-diesel, and are

unacceptable for use as fuel in any concentration in Kubota® engines.

Bio-diesel fuel blends up to B20 must comply with the following standards:

• EN14214 (European standard) and/or ASTM D-6751 (American standard).

• All applicable engines may operate with bio-diesel fuel up to a maximum B20

(20% bio- diesel blend) concentration.

Operating Conditions with B20 Bio-diesel Fuel Blends

Engine Warranty

Damages, performance or service concerns determined to be caused by the use

of bio-diesel fuel not meeting the specifications outlined above are not

considered to be defects in material or factory workmanship and are not covered

under warranty. The same applies to damages or other concerns induced by not

complying with the recommended operating conditions of Kubota® engines with

bio-diesel fuel.

OPERATION

HANDLING FUEL

WARNING

Diesel fuel is flammable and explosive under certain conditions.

• NEVER refuel with the engine running.

• Always refuel outdoors or in a well ventilated area.

• Fill the fuel tank with diesel fuel ONLY. Filling the fuel tank with gasoline may

result in a fire and will damage the engine.

• Remove flammable material containers from the box before filling them with

fuel.

• Do not smoke or allow open flames or sparks in or near the area where

refueling is performed or where fuel is stored.

• Wipe up all spills immediately.

• Keep sparks, open flames or any other form of ignition (match, cigarette,

static electricity source) well away when refueling.

• NEVER remove the fuel cap while the engine is running.

• NEVER overfill the fuel tank. Do not fill the tank neck.

• If fuel spills on your skin or clothing, immediately wash it off with soap and

water and change clothing.

REFUELING

The fuel tank filler cap is located on the left side of the vehicle near the driver’s

seat. Remove the cap and add the recommended fuel to the bottom of the filler

neck. Do not overfill.

OPERATION

COLD WEATHER OPERATION

Cold weather operation can result in fuel gelling if the incorrect fuel type is used.

Use the following fuel blending guideline to prevent this from occurring.

FUEL BLENDING GUIDELINE

Temperature No. 2 No. 1

+15 °F (-9 °C) 100% 0%

Down to -20 °F (-29 °C) 50% 50%

Below -20 °F (-29 °C) 0% 100%

COLD STARTING GUIDELINES

Temp. +20 °F (-7 °

C) to +15 °F

(-9 °C)

+15 °F (-9 °

C) to +5 °F

(-15 °C)

+5 °F (-15 °

C) to -20 °F

(-29 °C)

-20 °F (-29 °

C) to -25 °F

(-32 °C)

Fuel #2 Diesel 50/50 mix #1/#2 diesel #1 Diesel

5W-40

Synthetic

Diesel

Engine Oil

Optional Advised Required

Block heater Optional Advised Required

Battery

condition/

connections

Charged battery (12.8 VDC)

Proper glow

plug usage

(wait for the

light)

Wait for light at all temps

Oil pan

heater

Not needed Optional (helps to reduce

cranking)

BLOCK HEATER USE

If this vehicle will be operated when temperatures are in the +5 °F (-15 °C) to -25

°F (-32 °C) range, a block heater must be installed. Please see your dealer to

purchase a block heater kit.

OPERATION

NOTE

Block heater is not recommended when the vehicle is operated above +25 °F

(-4 °C).

BIO-DIESEL BLENDED FUEL

NOTICE

Never use bio-diesel blended fuel containing more than 20% bio-diesel in this

vehicle.

Bio-diesel blended fuel has unique qualities that should be considered

before using it in this vehicle:

• Cold weather conditions can lead to plugged fuel system components and

hard starting.

• Bio-diesel blended fuel is an excellent medium for microbial growth and

contamination which can cause corrosion and plugging of fuel system

components.

• Use of bio-diesel blended fuel may result in premature failure of fuel system

components, such as plugged fuel filters and deteriorated fuel lines.

• Shorter maintenance intervals may be required, such as cleaning the fuel

system and replacing fuel filters and fuel lines.

• Using bio-diesel blended fuels containing more than 20% bio-diesel can affect

engine life and cause deterioration of hoses, tubes, injectors, injector pump

and seals.

Use the following guidelines if bio-diesel blended fuel is used:

• Never use bio-diesel blended fuel containing more than 20% bio-diesel in this

vehicle.

• Ensure the fuel tank is as full as possible at all times to prevent moisture from

collecting in the fuel tank.

• Ensure that the fuel tank cap is securely tightened.

• Clean up any spilled fuel immediately to prevent damage to painted surfaces.

• Drain all water from the fuel filter daily before operating the vehicle.

• Do not exceed the engine oil change interval. Extended intervals can result in

engine damage.

• Before vehicle storage, drain the fuel tank, refill with 100% petroleum diesel

fuel, add fuel stabilizer and run the engine for at least 30 minutes.

NOTICE

Bio-diesel blended fuel does not have long term stability and should not be

stored for more than three months.

OPERATION

OPERATING CONDITIONS

NOTICE

Observe the following environmental operating conditions to maintain engine

performance and avoid premature engine wear.

• Avoid operating in the presence of chemical gases or fumes.

• Avoid operating in a corrosive atmosphere such as salt water spray.

• NEVER operate the engine in a floodplain unless proper precautions are

taken to avoid being subject to a flood.

• NEVER expose the engine to the rain.

• The standard range of ambient temperatures for the normal operation of

Kubota engines is from +5 °F (-15 °C) to +104 °F (+40 °C).

• If the ambient temperature exceeds +104 °F (+40 °C), the engine may

overheat and cause the engine oil to break down.

If the ambient temperature is between +5 °F (-15 °C) and -25 °F (-32 °C),

POLARIS recommends the use of a block heater.

OPERATION

STARTING THE ENGINE

NOTICE

NEVER use an engine starting aid such as ether. Engine damage will result.

Before operating this vehicle in cold weather, review the cold weather operation

information on the preceding pages. Always wait for the glow plug indicator light

to turn off before cranking the engine.

1. Always start the engine outdoors or in a well-ventilated area.

2. Sit in the driver's seat and fasten the seat belt.

3. Place the transmission in PARK.

4. Apply the brakes. Do not press the throttle pedal while starting the engine.

5. Turn the ignition switch to the ON position and wait for the glow plug indicator

light to turn off.

6. Turn the ignition key past the ON position to START. Engage the starter for a

maximum of five seconds. Release the key when the engine starts.

7. If the engine does not start within five seconds, release the ignition switch

and wait five seconds. Repeat steps 6 and 7 until the engine starts.

NOTICE

Operating the vehicle immediately after starting could cause engine damage.

Allow the engine to warm up for several minutes before operating the vehicle.

OPERATION

STOPPING THE ENGINE

For maximum engine life, allow the engine to idle, without load, for 5 minutes.

This will allow the engine components that operate at high temperatures, such

as the exhaust system, to cool slightly before the engine is shut down.

1. Release the throttle pedal completely and brake to a complete stop.

2. Place the transmission in PARK.

3. Engage the park brake.

4. Slowly release the brake pedal and make sure the transmission is in PARK

before exiting the vehicle.

5. Turn the engine off and remove the key to prevent unauthorized use.

WARNING

A rolling vehicle can cause serious injury. Always place the transmission in

PARK and engage the park brake when stopping the engine.

BRAKING

1. Release the throttle pedal completely.

TIP

When the throttle pedal is released completely and the engine speed drops

near an idle, the vehicle has no engine braking.

2. Press on the brake pedal evenly and firmly.

TIP

If the throttle pedal and brake pedal are applied simultaneously, engine power

may be limited.

3. Practice starting and stopping (using the brakes) until you’re familiar with the

controls.

OPERATION

AWD VEHICLE OPERATION

All Wheel Drive (AWD) is active at all times on the Polaris PRO XD 2000D AWD

and the Polaris PRO XD 4000D AWD. The front gearcase will automatically

engage any time the rear wheels lose traction. When the rear wheels regain

traction, the front gearcase will automatically disengage.

In some situations, the front gearcase may remain engaged. If this occurs, you

may notice increased steering effort and some vehicle speed restriction.

Perform the following procedure to disengage the front gearcase.

1. Stop the vehicle.

2. Operate in reverse for at least 10 ft (3 m).

3. Stop completely.

4. Shift into low gear and drive forward.

5. If the front gearcase remains engaged after following these instructions, see

your dealer or other qualified service person for service.

OPERATION

DRIVING PROCEDURES

1. All riders should wear substantial footwear, long pants and a close-fitting

shirt. A hard hat or helmet and approved eye protection are recommended

when appropriate for working or riding conditions.

2. Perform the pre-ride inspection.

3. Sit in the driver's seat and fasten the seat belt.

4. Place the transmission in PARK.

5. Engage the park brake.

6. Start the engine.

7. Apply the service brakes and shift the transmission into gear.

8. Check your surroundings and determine your path of travel.

9. Release the park brake.

10. Keeping both hands on the steering wheel, slowly release the brakes and

slowly depress the throttle with your right foot to begin driving.

11. Drive slowly. Practice maneuvering and using the throttle and brakes on level

surfaces.

12. Do not carry a passenger until you have at least two hours of driving

experience with this vehicle.

OPERATION

DRIVING WITH A PASSENGER

1. Perform the pre-ride inspection.

2. Make sure all passengers are at least 12 years of age and tall enough to

comfortably and safely sit in a passenger seat with the seat belt secured, put

both feet on the floor and grasp the hand hold.

3. All riders should wear substantial footwear, long pants and a close-fitting

shirt. A hard hat or helmet and approved eye protection are recommended

when appropriate for working or riding conditions.

4. Do not carry more than the recommended number of passengers for your

vehicle.

5. Allow a passenger to ride only in a passenger seat.

6. Slow down. Always travel at a speed appropriate for your skills, your

passengers’ skills, and operating conditions. Avoid unexpected or

aggressive maneuvers that could cause discomfort or injury to a passenger.

7. Vehicle handling may change with a passenger and/or cargo on board. Allow

more time and distance for braking.

8. Always follow all operating guidelines as outlined on safety labels and in this

manual.

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. Do not operate on excessively slippery surfaces.

When driving on slippery surfaces such as wet trails, loose gravel, or ice, be

alert for the possibility of skidding and sliding. Follow these precautions when

encountering slippery conditions:

1. Do not operate on excessively rough, slippery or loose terrain.

2. Slow down before entering slippery areas.

3. Maintain a high level of alertness, reading the trail and avoiding quick, sharp

turns, which can cause skids.

4. Correct a skid by turning the steering wheel in the direction of the skid. Never

apply the brakes during a skid.

DRIVING UPHILL

Whenever traveling uphill, follow these precautions:

1. Avoid excessively steep hills.

2. Always travel straight uphill.

3. Keep both feet on the floor.

4. Always check the terrain carefully before ascending any hill. Never climb hills

with excessively slippery or loose surfaces.

5. Proceed at a steady rate of speed and throttle opening. Never open the

throttle suddenly.

6. Never go over the crest of a hill at high speed. An obstacle, a sharp drop, or

another vehicle or person could be on the other side of the hill.

OPERATION

DRIVING ON A SIDEHILL (SIDEHILLING)

Driving on a sidehill is not recommended. Improper procedure could cause loss

of control or rollover. Avoid crossing the side of any hill unless absolutely

necessary.

If crossing a sidehill is unavoidable, follow these precautions:

1. Slow down.

2. Exercise extreme caution.

3. Avoid crossing the side of a steep hill.

DRIVING DOWNHILL

When driving downhill, follow these precautions:

1. Avoid excessively steep hills.

2. Always descend a hill with the direction selector switch on forward. Never

descend a hill with the switch on neutral.

3. Drive straight downhill. Avoid descending a hill at an angle, which would

cause the vehicle to lean sharply to one side. Travel straight downhill when

possible.

4. Slow down.

5. Apply the brakes slightly to aid in slowing.

OPERATION

DRIVING THROUGH WATER

Your vehicle can operate through water up to a maximum recommended depth

equal to the floorboards.

NOTICE

Immersion can result in major damage if the vehicle isn't serviced correctly and

promptly. After immersion, always take the vehicle to your dealer service. Do

not start the engine! If it's impossible to bring the vehicle to your dealer before

starting the engine, perform the service outlined in the Vehicle Immersion

section, and take the vehicle to your dealer at the first opportunity.

Follow these procedures when operating through water:

1. Determine water depths and current before entering water.

2. Choose a crossing where both banks have gradual inclines.

3. Proceed slowly, avoiding rocks and obstacles.

4. Avoid operating through deep or fast-flowing water.

WARNING

The large tires on your vehicle may cause the vehicle to float in deep or fast-

flowing water, which could result in loss of control and lead to serious injury or

death. Never cross deep or fast-flowing water with your vehicle

5. After leaving water, always dry the brakes by applying light pressure to the

pedal repeatedly until braking action is normal.

NOTE

After running your vehicle in water, it's critical that you perform the services

outlined in the Periodic Maintenance Chart. Give special attention to engine oil,

transmission oil, front and rear gearcases (if equipped), and all grease fittings.

OPERATION

DRIVING IN REVERSE

NOTICE

Shifting into reverse automatically activates the reverse alert beeper.

Follow these precautions when operating in reverse:

1. Always check for obstacles or people behind the vehicle. Always inspect left

and right fields of vision before backing.

2. Always avoid backing downhill.

3. Back slowly.

4. Apply the brakes lightly for stopping.

5. Avoid turning at sharp angles.

6. Never open the throttle suddenly.

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. Travel slowly and use extra caution when operating on unfamiliar terrain. Not

all obstacles are immediately visible.

4. Avoid operating over large obstacles such as large rocks and fallen trees. If

unavoidable, use extreme caution and operate slowly.

5. Always have all passengers dismount and move away from the vehicle

before operating over an obstacle that could cause a rollover.

OPERATION

PARKING THE VEHICLE

To park the vehicle, do the following:

1. Apply the brakes. Stop the vehicle on a level surface.

2. 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.

3. Place the transmission in PARK.

4. Turn the engine off.

5. Engage the park brake.

6. Slowly release the brake pedal and make sure the transmission is in PARK

before exiting the vehicle.

7. Remove the ignition switch key to prevent unauthorized use.

PARKING ON AN INCLINE

Avoid parking on an incline if possible. If it's unavoidable, follow these

precautions:

1. Apply the brakes.

2. Place the transmission in PARK.

3. Engage the park brake.

4. Turn the engine off.

5. Slowly release the brake pedal and make sure the transmission is in PARK

before exiting the vehicle.

6. Block the rear wheels on the downhill side.

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. 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. The combined weight of these items must not

exceed the maximum weight capacity.

REDUCE SPEED AND ALLOW GREATER DISTANCES FOR BRAKING

WHEN HAULING CARGO.

Always load the cargo box with the load as far forward and as low as possible.

When operating over rough or hilly terrain, reduce speed and cargo to maintain

stable driving conditions.

Always operate the vehicle with extreme care when hauling or towing loads.

Slow down and drive in the lowest gear available. Always use LOW gear when

towing or hauling heavy loads.

SECURE ALL LOADS BEFORE OPERATING. Unsecured loads can create

unstable operating conditions, which could result in loss of control of the

vehicle.

OPERATE ONLY WITH STABLE AND SAFELY ARRANGED LOADS. When

handling off-centered loads that cannot be centered, securely fasten the load

and operate with extra caution. Always attach the tow load to the hitch point

designated for your vehicle.

HEAVY LOADS CAN CAUSE BRAKING AND CONTROL PROBLEMS. Use

extreme caution when applying brakes with a loaded vehicle. Avoid terrain or

situations that may require backing downhill.

USE EXTREME CAUTION when operating with loads that extend over the

rack sides. Stability and maneuverability may be adversely affected, causing a

rollover.

DO NOT TRAVEL FASTER THAN THE RECOMMENDED SPEEDS. Vehicle

should never exceed 10 mph (16 km/h) while towing a load on a level grass

surface. Vehicle speed should never exceed 5 mph (8 km/h) when towing

loads in rough terrain, while cornering, or while ascending or descending a hill.

LOAD CAPACITY

Your 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.

OPERATION

WARNING

Driving with passengers in the cargo box can result in serious injury or death.

Never allow passengers to ride in the cargo box. Passengers must always ride

in the cab with seat belts fastened securely.

TOWING LOADS

WARNING

Towing improperly can alter vehicle handling and may cause loss of control or

brake instability.

Always follow these precautions when towing:

1. Never load more than 250 lb (113.4 kg) tongue weight on the towing bracket.

2. When towing a disabled vehicle, place the disabled vehicle’s transmission in

neutral. Do not operate the vehicle faster than 10 mph (16 km/h) when

towing.

3. Towing a trailer increases braking distance. Do not operate the vehicle faster

than 10 mph (16 km/h) when towing.

4. Do not tow more than the recommended weight for the vehicle.

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.

6. The total load (operator, accessories, cargo and weight on hitch) must not

exceed the maximum weight capacity of the vehicle.

MODEL

TOTAL

TOWED

LOAD

WEIGHT

(LEVEL

GROUND)

TOTAL

TOWED

LOAD

WEIGHT

(15° GRADE)

TOTAL HITCH

VERTICAL

WEIGHT

MAXIMUM

TOWING

SPEED

Polaris PRO

2500 lb

(1134 kg)

850 lb

(386 kg)

250 lb

(113.4 kg)

10 mph

(16 km/h)

OPERATION

DUMPING THE CARGO BOX

To dump the cargo box, do the following:

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. Apply the brakes. Place the transmission in PARK.

3. Engage the park brake.

4. Ensure that the cargo is positioned evenly or toward the front of the cargo

box.

5. Release the tailgate by pulling up on the tailgate latch.

WARNING

If the weight distribution on the box is located toward the rear of the box when

the release lever is pulled forward, the box may dump unexpectedly and cause

serious injury to the operator or bystanders. Never operate the Release Lever

dump lever without ensuring that the load is positioned evenly or at the front of

the box.

6. Stand clear and pull up on the cargo box release leverq. Lift the front of the

cargo box to dump the cargo.

OPERATION

7. 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.

The rear tires could also catch the rear of a raised box, damaging the vehicle

and creating hazardous driving conditions. Never operate this vehicle with the

cargo box in the raised position.

OPERATION

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.

Your winch may have a cable made of either wire rope or specially designed

synthetic rope. The term “winch cable” will be used for either unless noted

otherwise.

WINCH SAFETY PRECAUTIONS

1. Read all sections of this manual.

2. Never use alcohol or drugs before or while operating the winch.

3. Never allow children under 16 years of age to operate the winch.

4. Always wear eye protection and heavy gloves when operating the winch.

5. Always keep body, hair, clothing and jewelry clear of the winch cable, fairlead

and hook when operating winch.

6. Never attempt to “jerk” a load attached to the winch with a moving vehicle.

See the section on page 97.Shock Loading

7. Always keep the area around the vehicle, winch, winch cable, and load clear

of people (especially children) and distractions while operating the winch.

8. Always turn the vehicle ignition power OFF when it and the winch are not

being used.

9. Always be sure that at least five (5) full turns of winch cable are wrapped

around the winch drum at all times. The friction provided by this wrapped

cable allows the drum to pull on the winch cable and move the load.

10. Always apply your vehicle’s park brake and/or park mechanism to hold the

vehicle in place during winching. Use wheel chocks if needed.

11. Always align the vehicle and winch with the load directly in front of the

vehicle as much as possible. Avoid winching with the winch cable at an angle

to the winching vehicle’s centerline whenever possible.

WINCH GUIDE

22. Never winch the hook fully into the winch. This can cause damage to winch

components.

23. Unplug the remote control from the vehicle when the winch is not in use to

prevent inadvertent activation and use by unauthorized persons.

24. Never grease or oil the winch cable. This will cause the winch cable to collect

debris that will shorten the life of the cable.

WINCH OPERATION

Read the Winch Safety Precautions in the preceding pages before using your

winch.

TIP

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.

Each winching situation is unique.

• Take your time to think through the winching you are about to do.

• Proceed slowly and deliberately.

• Never hurry or rush during winching.

• Always pay attention to your surroundings.

• You may need to change your winching strategy if it is not working.

• Always remember that your winch is very powerful.

• There are simply some situations that you and your winch will not be able to

deal with. Do not be afraid to ask others to help when this happens.

1. Always inspect the vehicle, winch, winch cable and winch controls for any

signs of damage or parts in need of repair or replacement before each use.

Pay particular attention to the first 3 ft (1 m) of winch cable if the winch is

being used (or has been used) for lifting an accessory plow assembly.

Promptly replace any worn or damaged cable.

2. Never operate a winch or a vehicle in need of repair or service.

3. Always apply your vehicle’s park brake and/ or park mechanism to hold the

vehicle in place during winching. Use wheel chocks if needed.

WINCH GUIDE

4. Always use the hook strap when handling the hook.

WARNING

Never put your fingers into the hook. This could lead to SEVERE INJURY.

• Attach the hook itself onto the load or use a tow strap or chain to secure

the load to the winch cable.

TIP

A “tow strap” is NOT intended to stretch. A “recovery strap” is designed to

stretch.

WINCH GUIDE

WARNING

Never use a recovery strap when winching due to the excessive energy that

can be released if the winch cable breaks. This can result in SEVERE INJURY

or DEATH. See the section on page 97.Shock Loading

• Never hook the winch cable back onto itself. This will damage the winch

cable and may result in winch cable failure.

WARNING

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.

• 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. Sharp cables and

chains can damage and even kill trees. Please remember to Tread

Lightly® (treadlightly.org).

• Before operating the winch, be sure that the safety latch on the winch

cable hook is fully seated when the load is attached.

• Never operate your winch with a damaged hook or latch. Always replace

damaged parts before using the winch.

5. Never remove the hook strap from the hook.

6. Release the winch clutch and pull out the winch cable.

7. Pulling out as much cable as possible maximizes the winch’s pulling

capacity. Always be sure that at least five (5) full turns of winch cable are

wrapped around the winch drum at all times. The friction provided by this

wrapped cable allows the drum to pull on the winch cable and move the load.

WINCH GUIDE

WINCH MAINTENANCE AND SERVICE SAFETY

WARNING

Improper or lack of winch maintenance and service could lead to SEVERE

INJURY or DEATH. Always follow all winch instructions and warnings in this

manual.

1. Always inspect your winch before each use. Inspect for worn or kinked winch

cable. Also inspect for worn or loose parts including mounting hardware.

2. Permit your winch motor to cool down prior to servicing your winch.

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.

5. Some winch models use wire rope as the winch cable. Other winches use a

specially designed synthetic rope as the winch cable.

6. Never replace a synthetic-rope winch cable with a consumer-grade polymer

rope such as can be purchased in a hardware store. Although they may look

similar, they are NOT alike. A polymer rope not designed for winch use will

stretch and store excessive energy when winching.

WARNING

Failure of a stretched rope under winching conditions will release all of the

stored energy. This will increase the chances of SEVERE INJURY or DEATH.

WINCH GUIDE

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 5100-1C. Federal law requires that this

spark arrester be installed and functional when the vehicle is operated on public

lands.

Operation of off-road vehicles on public lands in the U.S.A. is regulated by 43

CFR 420. Violations are subject to monetary penalties. Federal regulations can

be viewed online at .www.gpoaccess.gov/ecfr/

EXHAUST EMISSION CONTROL SYSTEM

Exhaust emissions are controlled by engine design. A fuel injection system

controls fuel delivery. The engine and fuel injection components are set at the

factory for optimal performance and are not adjustable.

Your engine is designed to operate on ultra low sulfur diesel fuel only. Use of any

other fuel may result in your engine no longer operating in compliance with

emissions requirements.

ELECTROMAGNETIC INTERFERENCE

CAN ICES-2/NMB-2

This diesel vehicle complies with Canada ICES-002.

This vehicle complies with the EMC requirements of UN ECE Regulation 10.

Non-ionizing Radiation: This vehicle emits some electromagnetic energy.

People with active or non-active implantable medical devices (such as heart

monitoring or controlling devices) should review the limitations of their device

and the applicable electromagnetic standards and directives that apply to this

vehicle.

EMISSION CONTROL SYSTEMS

100

MAINTENANCE

PERIODIC MAINTENANCE CHART

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 may be used for such service.

It is a potential violation of the Clean Air Act if a part supplied by an aftermarket

parts manufacturer reduces the effectiveness of the vehicle’s emission controls.

Tampering with emission controls is prohibited by federal law.

Owners are responsible for performing the scheduled maintenance identified in

this owner’s manual.

Careful periodic maintenance will help keep your vehicle in the safest, most

reliable condition. Inspection, adjustment and lubrication of important

components are explained in the periodic maintenance chart.

Inspect, clean, lubricate, adjust and replace parts as necessary. When

inspection reveals the need for replacement parts, genuine POLARIS parts are

available from your POLARIS dealer.

Record maintenance and service in the Maintenance Log at the end of the

manual.

CAUTION

Service and adjustments are important for proper vehicle operation. If you're

not familiar with safe service and adjustment procedures, have a qualified

dealer perform these operations.

Vehicles subjected to heavy or severe use patterns must be inspected and

serviced more frequently.

SEVERE USE DEFINITION

• Frequent immersion in mud, water or sand

• Prolonged low speed, heavy load operation

BREAK-IN PERIOD

The break-in period consists of the first 50 hours of operation. Careful treatment

of a new engine and drive components will result in more efficient performance

and longer life for these components.

101

MAINTENANCE

• Drive vehicle slowly at first while varying the throttle position. Do not operate

at sustained idle.

• Perform regular checks on fluid levels and other areas outlined on the daily

pre-ride inspection checklist.

• Change both the engine oil and filter after 50 hours or one month.

MAINTENANCE INTERVALS

The maintenance interval charts list required maintenance and inspection based

on vehicle hours / miles. Each table states a service that corresponds to the

hour / mile chart below. Some items or components may need to be serviced

more often due to severe use, such as operation in water, extreme

temperatures, or under severe loads.

HOUR / MILEAGE SERVICE

First 50 hours / 500 miles (800 km) Break-In Service — Perform the 200

Hour Check List (Table 2)

Every 50 hours / 500 miles (800 km)

thereafter

See Table 1

Every 200 hours / 2000 miles (3200

km) thereafter

See Table 2

102

MAINTENANCE

SERVICE CODES

XU - PERFORM THESE PROCEDURES MORE OFTEN FOR VEHICLES

SUBJECTED TO SEVERE USE.

D - HAVE AN AUTHORIZED POLARIS DEALER OR OTHER QUALIFIED

PERSON PERFORM THESE SERVICES.

E - EMISSION CONTROL SYSTEM SERVICE (CALIFORNIA).

BREAK-IN SERVICE

FIRST 50 HOURS / 500 MILES (800 KM)

Perform the 200 Hour Checklist (Table 2) for Break-In Service

TABLE 1.

EVERY 50 HOURS / 500 MILES (800 KM) SERVICE

CODE ITEM ACTION

XU / E Engine Oil & Filter Change Inspect oil level (Break-in oil and

filter change at first 50 hrs;

perform every 200 hrs, thereafter)

XU Brake Pads / Parking Brake

Pads

Inspect pad wear; contact dealer

to replace if worn beyond service

limit

E Fuel System Turn key on to pressurize fuel

pump; check lines and fittings for

leaks and abrasion, contact dealer

for repairs

XU Parking Brake Inspect operation; contact dealer

to adjust tension as needed

Battery Check terminals; clean if

necessary

Fan/Alternator Belt Inspect belt quality and tension-

Adjust/replace as necessary

XU Front Gearcase Lubricant Inspect / add lubricant if needed

XU Transmission Lubricant (AGL) Inspect / add lubricant if needed

103

MAINTENANCE

TABLE 1.

EVERY 50 HOURS / 500 MILES (800 KM) SERVICE

CODE ITEM ACTION

E Throttle Pedal / Throttle

Linkage

Inspect for proper operation and

smooth travel; contact dealer if

any concerns are found

XU Air Filter / Air Box Inspect; replace filter as needed,

or yearly (Item part of Pre-Ride

Inspection)

E Air Intake Ducts / Adapters Inspect ducts for proper sealing,

and ensure clamps are tight;

contact dealer for any repairs

Shift Cable / Linkage Inspect; Contact dealer to adjust

as needed,

Steering Inspect for loose components and

torn boots; contact dealer to

replace parts as needed

XU Rear Stabilizer Bar Lubricate and inspect bushings

XU Radiator Inspect; clean external surfaces

E Fuel Filter / Water Separator Drain every 50 hrs (normal

conditions with quality fuel) or

daily (severe conditions with poor

fuel quality)

XU Axles Inspect boots for damage

104

MAINTENANCE

TABLE 2.

EVERY 200 HOURS / 2000 MILES (3200 KM) SERVICE

CODE ITEM ACTION

XU / E Engine Oil & Filter Change Perform a break-in oil and filter

change at first 50 hrs; perform

every 200 hrs thereafter

XU / D Brake Pads / Parking Brake

Pads

Inspect pad wear; replace if worn

beyond service limit

D / E Fuel System Turn key on to pressurize fuel

pump; check lines and fittings for

leaks and abrasion,Check for

leaks at fill cap, and fuel pump.

XU / D Parking Brake Inspect operation; adjust tension

as needed

Battery Check terminals; clean; test

E Throttle Pedal / Throttle

Linkage

Inspect for proper operation and

smooth travel; contact dealer if

any concerns are found

E Air Intake Ducts/Adapters Inspect ducts for proper sealing,

and ensure clamps are tight;

contact dealer for any repairs

XU Air Filter / Air Box Replace filter (Item part of Pre-

Ride Inspection)

Shift Cable / Linkage Inspect; adjust as needed

D Steering Inspect for loose components and

torn boots; replace parts as

needed

Fan/Alternator Belt Inspect belt quality and tension-

Adjust/replace as necessary

D Cooling System Inspect coolant strength; pressure

test system Replace coolant every

5 years.

D Drive Belt Inspect; replace as needed

XU Front Gearcase Lubricant Change lubricant

105

MAINTENANCE

TABLE 2.

EVERY 200 HOURS / 2000 MILES (3200 KM) SERVICE

CODE ITEM ACTION

XU Transmission Lubricant (AGL) Change lubricant

E Fuel Filter / Water Separator Replace filter

XU Radiator Inspect; clean external surfaces

XU Cooling Hoses Inspect for leaks; pressure test

system

XU / D Engine Mounts Inspect, torque to specification

Exhaust Silencer / Pipe Inspect

XU Wiring Inspect for wear, routing, security;

inspect connectors subjected to

water, mud, etc.

D Clutches (Drive and Driven) Inspect; clean; replace worn parts

D Wheel Bearings Inspect; replace as needed

Tires / Wheels Inspect tire tread; rotate as

needed

XU Shocks Visually inspect shock seals,

replace as necessary

D Brake Fluid Inspect level and quality, Change

fluid every 2 years (DOT 4)

D Front Wheel Alignment Inspect toe alignment, and adjust

if necessary

XU Suspension Bushings Inspect front and rear suspension

bushings; replace if necessary

XU Rear Stabilizer Bar Lubricate grease zerks and

inspect bushings

XU Prop Shafts Lubricate grease zerks

XU Axles Inspect boots for damage

106

MAINTENANCE

LUBRICATION RECOMMENDATIONS

Check and lubricate all components at the intervals outlined in the Periodic

Maintenance Chart, or more often under severe use, such as wet or dusty

conditions. Items not listed in the chart should be lubricated at the general

lubrication interval.

ITEM LUBE METHOD

Engine Oil POLARIS Diesel Oil (SAE

15W-40)

Add to proper level on dipstick.

See page 107.

Brake Fluid DOT 4 Brake Fluid Maintain level between fill

lines.

See page 146.

Transmission Oil

(Main Gearcase)

AGL Gearcase Lubricant &

Transmission Fluid

See page 115.

Demand Drive Fluid

(Front Gearcase)

Demand Drive Fluid See page 116.

Prop Shaft U-Joint Grease Locate fittings and grease.

ENGINE OIL

Always check and change the oil at the intervals outlined in the Periodic

Maintenance Chart. Always use the recommended engine oil. Always change

the oil filter whenever changing oil.

WARNING

Vehicle operation with insufficient, deteriorated, or contaminated engine oil will

cause accelerated wear and may result in engine seizure, accident and injury.

Always perform the maintenance procedures as outlined in the Periodic

Maintenance Chart.

107

MAINTENANCE

OIL CHECK

This engine has a wet-sump design, meaning the engine oil is contained in the

bottom of the crankcase. To check the oil level, follow the procedure listed

below:

1. Check the oil when the engine is cold and safe to touch.

2. Make sure that the vehicle is on a level surface and that the transmission in

PARK.

3. Locate the dipstick qon the right side of the unit.

4. Remove the dipstick and wipe it dry with a clean cloth.

5. Reinstall the dipstick and push it into place.

NOTICE

Make certain the dipstick is inserted all the way into the dipstick tube to keep

the depth of the dipstick consistent.

6. Remove the dipstick and check the oil level.

109

MAINTENANCE

7. Add the recommended oil as necessary to bring the oil level within the SAFE

range on dipstick. Do not overfill.

NOTICE

A rising oil level between checks during cold weather operation can indicate

contaminants such as gas or moisture collecting in the crankcase. If the oil

level is over the upper mark, change the oil immediately.

110

MAINTENANCE

4. Place a drain pan under the engine crankcase and remove the drain plugq.

Allow the oil to drain completely.

5. Using an oil filter wrench, turn the oil filter wcounter-clockwise to remove it.

6. Using a clean dry cloth, clean the filter sealing surface on the engine

crankcase.

112

MAINTENANCE

20.Add the recommended oil as necessary to bring the oil level within the SAFE

range on dipstick. Do not overfill.

NOTICE

Add oil slowly, to make sure oil does not get into the breather or intake.

21.When finished, reinstall the oil fill cap and oil dipstick.

22.Dispose of used oil and filter properly.

114

MAINTENANCE

GEARCASES

GEARCASE SPECIFICATION CHART

GEARCASE LUBRICANT CAPACITY FILL PLUG

TORQUE

DRAIN PLUG/

LEVEL

CHECK PLUG

TORQUE

Transmission

(Main

Gearcase)

AGL Gearcase

Lubricant &

Transmission

Fluid

41 fl oz

(1200 mL)

10–14 ft-lbs

(14–19 N·m)

10–14 ft-lbs

(14–19 N·m)

Demand Drive

Unit (Front

Gearcase)

Demand Drive

Fluid

9.3 fl oz

(275 mL)

8–10 ft-lbs

(11–14 N·m)

11 ft-lbs

(15 N·m)

TRANSMISSION (MAIN GEARCASE)

TRANSMISSION OIL CHECK

Always check and change the transmission oil at the intervals outlined in the

Periodic Maintenance Chart. Maintain the oil level even with the bottom thread

of the fill plug hole.

The fill plug is located on the rear of the gearcase. Maintain the fluid level at the

bottom of the fill plug hole.

To check the transmission fluid, do the following:

1. Position the vehicle on a level

surface.

2. Remove the fill plug q.

3. Check the fluid level.

4. Add the recommended fluid to the

bottom of the fill plug hole. Do not

overfill.

5. Reinstall the fill plug. Torque to

specification.

115

MAINTENANCE

TRANSMISSION OIL CHANGE

The drain plug is located on the bottom of the gearcase. Access the drain plug

through the hole in the skid plate.

1. Remove the fill plug q.

2. Place a drain pan under the drain

plug w.

3. Remove the drain plug. Allow the

fluid to drain completely.

4. Clean and reinstall the drain plug.

Torque to specification.

5. Add the recommended fluid to the

bottom of the fill plug hole. Do not

overfill.

6. Reinstall the fill plug. Torque to

specification.

7. Check for leaks. Discard used fluid

properly.

DEMAND DRIVE (FRONT GEARCASE) (IF

EQUIPPED)

DEMAND DRIVE OIL CHECK

Always check and change the demand drive fluid at the intervals outlined in the

Periodic Maintenance Chart. Maintain the oil level even with the bottom thread

of the fill plug hole. Refer to the Gearcase Specifications Chart for

recommended lubricants, capacities and torque specifications.

The front gearcase fill plug qis located on the right side of the front gearcase.

1. Position the vehicle on a level

surface.

2. Remove the fill plug q. Check the

oil level.

3. Add the recommended oil as

needed.

4. Reinstall the fill plug. Torque to

specification.

116

MAINTENANCE

DEMAND DRIVE OIL CHANGE

1. Support the vehicle securely with a jackstand.

2. Remove the front tire on the passenger's side for ease of access (optional).

3. Remove the fill plug.

4. Place a drain pan under the drain plugwon the bottom right-hand side.

5. Remove the drain plug. Drain the oil.

6. Clean and reinstall the drain plug. Torque to specification.

7. Add the recommended fluid to the bottom of the fill plug hole. Do not overfill.

8. Reinstall the fill plug. Torque to specification.

9. Check for leaks.

10. Discard used oil properly.

GREASE LUBRICATION POINTS

There are grease fittings at the rear stabilizer bar bushings and on the front

propshaft yokes. Apply grease until all traces of water have been purged out at

each of these areas.

ITEM LUBE REC METHOD FREQUENCY

Propshaft

Yoke

Premium U-Joint

Lubricant

Grease middle q

fitting

Grease fittings

every 500 miles

(800 km);

Grease before

long periods of

storage, and

after thoroughly

washing or

submerging the

vehicle

Rear

Stabilizer

Bar

Bushings

Premium All Season

Grease Grease fittings w

Grease fittings

every 500 miles

(800 km);

Grease before

long periods of

storage, and

after thoroughly

washing or

submerging the

vehicle

117

MAINTENANCE

BASE

CREW

118

MAINTENANCE

Rear Stabilizer Bar Bushings, Right and Left Side

119

MAINTENANCE

COOLING SYSTEM

The engine coolant level is controlled or maintained by the recovery system. The

recovery system components are the overflow bottle, radiator filler neck, radiator

pressure cap and connecting hose.

As coolant operating temperature increases, the expanding (heated) excess

coolant is forced out of the radiator, past the pressure cap, and into the overflow

bottle. As engine coolant temperature decreases, the contracting (cooled)

coolant is drawn back up from the tank, past the pressure cap, and into the

radiator.

Some coolant level drop on new vehicles is normal as the system is purging

itself of trapped air. Observe coolant levels and maintain as recommended by

adding coolant to the overflow bottle.

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.

Any time the cooling system has been drained for maintenance or repair,

replace the coolant with fresh Antifreeze 50/50 Premix. If the recovery bottle has

run dry, the level in the radiator should be inspected. Add coolant as needed.

RADIATOR AND COOLING FAN

Always check and clean the screen and radiator fins at the intervals outlined in

the Periodic Maintenance Chart. Do not obstruct or deflect air flow through the

radiator by installing unauthorized accessories in front of the radiator or behind

the cooling fan. Interference with the radiator air flow can lead to overheating

and consequent engine damage.

NOTICE

Washing the vehicle with a high-pressure hose could damage the radiator fins

and impair the radiator's effectiveness. Using a high-pressure system is not

recommended.

120

MAINTENANCE

RADIATOR COOLANT LEVEL

Always check and clean the screen and

radiator fins at the intervals outlined in

the Periodic Maintenance Chart. Do not

obstruct or deflect air flow through the

radiator by installing unauthorized

accessories in front of the radiator or

behind the cooling fan. Interference with

the radiator air flow can lead to

overheating and consequentially,

engine damage.

1. Lift the hood.

CAUTION

Escaping steam can cause burns. Never remove the pressure cap while the

engine is warm or hot. Always allow the engine to cool before removing the

pressure cap.

2. Slowly remove the radiator cap q.

3. View the coolant level through the opening.

4. Use a funnel and slowly add coolant as needed.

TIP

This procedure is required only if the cooling system has been drained for

maintenance and/or repair. But if the overflow bottle has run dry, the level in

the radiator should also be inspected.

5. 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.

121

MAINTENANCE

OVERFLOW BOTTLE COOLANT LEVEL

Always check and change the coolant at the intervals outlined in the Periodic

Maintenance Chart. Maintain the coolant level between the minimum and

maximum marks on the bottle (when the fluid is cool).

1. Position the vehicle on a level surface.

2. Lift the hood. View the coolant level in the overflow bottleq.

3. If the coolant level is below the safe operating range, lift the hood and locate

the overflow bottle lid. Remove the cap and use a funnel to add coolant

through the filler opening. Reinstall the cap.

TIP

If coolant must be added often, or if the overflow bottle runs completely dry,

there may be a leak in the system. Your dealer can inspect the cooling system.

122

MAINTENANCE

FUEL LEAK INSPECTION

1. Lift the driver’s seat and the box to gain access to the fuel lines.

2. Inspect all fuel lines for leaks, cracks, and loose connections.

123

MAINTENANCE

BELT REMOVAL

If a belt fails, always clean any debris from the clutch air duct and from the clutch

and engine compartments when replacing the belt.

WARNING

Failure to remove ALL debris when replacing the belt could result in vehicle

damage, loss of control and severe injury or death.

NOTICE

Inspect the entire clutch outlet duct (including the outlet duct screen) when

replacing a drive belt. Remove any debris found in the outlet duct or outlet duct

screen.

To remove the belt, do the following:

1. Remove the nine fasteners qthat retain the outer clutch cover.

NOTICE

Removal of left rear wheel or left rear shock is NOT necessary for belt

replacement.

2. Pull the clutch cover forward and slide towards the front of the vehicle as

shown above.

125

MAINTENANCE

BELT INSPECTION

To inspect the drive belt, do the following:

1. Inspect belt for hour-glassing (extreme circular wear in at least one spot and

on both sides of the belt). Hour glassing occurs when the drive train does not

move and the drive clutch engages the belt.

2. Inspect belt for loose cords, missing cogs, cracks, abrasions, thin spots, or

excessive wear. Compare belt measurements with a new drive belt. Replace

if necessary.

3. Belts with thin spots, burn marks, etc., should be replaced to eliminate noise,

vibration, or erratic PVT operation.

127

MAINTENANCE

BELT INSTALLATION

NOTICE

Be sure to install belt in the same direction as it was removed.

1. With the clutch spreader toolqinstalled, loop the belt over the drive clutch

and over the driven clutch.

2. Rotate the driven clutch and walk the belt into the clutch.

3. Remove the clutch spreader tool from driven clutch.

4. Rotate / spin the driven clutch and belt approximately 5-7 times to properly

seat the belt in the driven clutch.

5. Install the clutch cover into wheel well as shown above.

6. Rotate clutch cover over A-Arm was shown below. Use care not to damage

intake boots or electrical harness.

128

MAINTENANCE

7. Pull clutch cover backwards and align with bolt holes on inner clutch cover as

shown below.

8. Install and torque the outer clutch cover bolts to specification.

TORQUE

PVT Outer Cover Fasteners: 35 (4 N·m)

129

MAINTENANCE

POLARIS VARIABLE TRANSMISSION (PVT)

DRYING

There may be some instances when water is ingested into the PVT system. Use

the following instructions to dry it out before operating:

1. Position the vehicle on a level surface.

2. Remove the red drain plug on the outer clutch cover. Allow the water to drain

completely. Reinstall the drain plug.

3. Place the transmission in PARK.

4. Start the engine.

5. Apply varying throttle for 10-15 seconds to expel the moisture and air-dry the

belt and clutches. Do not hold the throttle wide open for more than five (5)

seconds.

6. Allow the engine RPM to settle to idle speed. Apply the brakes. Shift the

transmission to the lowest available range.

7. Test for belt slippage. If the belt slips, repeat the process.

8. Your vehicle requires service as soon as possible. Your POLARIS dealer can

assist.

130

MAINTENANCE

SHIFT CABLE / LINKAGE INSPECTION

Ensure that shift cable/linkage is clean, free of debris, operation is smooth and

cable boot is not damaged. If operation is not smooth or if the cable boot is

damaged or torn, contact an authorized dealer for service.

VEHICLE IMMERSION

WARNING

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 vehicle in for service before starting it, follow the

steps outlined below:

1. Move the vehicle to dry land, or at the very least to water below the

floorboard.

2. Inspect the air box for water.

NOTICE

Do not attempt to start the engine if water is present in the air box. Engine

damage will result. Take the vehicle in for service before starting the engine.

3. If the air box is wet but has no visible water, dry the air box.

4. Thoroughly dry the air pre-cleaner located under the hood.

131

MAINTENANCE

5. Take the vehicle in for service as soon as possible, whether you succeed in

starting it or not. Your POLARIS dealer can provide the required service.

6. If water has been ingested into the PVT, follow the procedure for drying in the

POLARIS Variable Transmission (PVT) Drying section.

FILTER SYSTEMS

AIR FILTER INSPECTION / REPLACEMENT

Inspect the air filter at the intervals

outlined in the Periodic Maintenance

Chart. In extremely dusty conditions, air

filter replacement will be required more

often.

1. Locate the air filter on the left side of the unit.

2. Release the two airbox wcover latches.

132

MAINTENANCE

3. Remove the cover eto access the air filter element r.

4. Inspect the airbox for oil or water deposits. Wipe away any deposits with a

clean shop towel.

NOTICE

Air filter removal is not needed for inspection-only.

IMPORTANT

If the filter has been soaked with fuel or oil it must be replaced.

DO NOT attempt to clean the air filter.

5. Place the air filter into the airbox. Reposition the airbox cover and install the

two retaining latches.

NOTICE

Make sure the hinge pins are properly seated when reassembling the airbox

133

MAINTENANCE

AIR INTAKE DUCTS INSPECTION

Inspect the intake ducts between the filter and engine for loose connections,

cracking, etc. Ensure clamps are tight.

SPARK ARRESTER

WARNING

• Never operate the vehicle without the spark arrester.

• Remove any combustible materials from the area.

Failure to heed the following warnings while servicing the spark arrestor

could result in serious injury or death.

• Never run the engine in an enclosed area. Exhaust contains poisonous

carbon monoxide gas that can cause loss of consciousness or death in a

very short time.

• Do NOT perform service on the spark arrester while the system is HOT.

Exhaust system temperatures can reach extreme temperatures. Allow

components to cool sufficiently before proceeding.

• Do not stand behind or in front of the vehicle while purging the exhaust

system.

• Never go under the vehicle while it is inclined.

• Wear eye protection and gloves while servicing.

134

MAINTENANCE

Use the following procedure to periodically purge accumulated carbon from the

exhaust pipe.

1. Turn off engine and allow exhaust to cool sufficiently.

2. Remove the spark arrester from the tailpipe of the muffler.

3. Remove any debris from spark arrester and the tailpipe.

4. Inspect spark arrester for holes in mesh screen. Replace as needed.

5. Replace spark arrester and torque bolt to specification.

TORQUE

Spark Arrester Bolt: 8 ft-lbs (11 N·m)

135

MAINTENANCE

ALTERNATOR BELT

Belt Adjustment

Check the alternator belt at the correct service interval as outlined in the Periodic

Maintenance Chart.

Stop the machine on a flat level surface. Put the gear selector in Park, stop the

engine and exit the vehicle. See the Stopping the Engine section.

1. Raise the cargo box.

2. The belt tension is correct with 0.3 in (7.6 mm) of belt deflection at the mid

span at the top of the belt q, when 20 lb (89) of force is applied to the belt.

3. If the belt tension is not correct, loosen the mounting boltwand adjustment

bolt e.

4. Move the top of the alternatorrto tighten the belt.

5. Tighten the adjustment bolt to 20 ft-lbs (27 N·m).

6. Tighten the mounting bolt to 20 ft-lbs (27 N·m).

7. Lower the cargo box.

136

MAINTENANCE

FUEL FILTER / WATER SEPARATOR

The fuel filter/water separator is located under the seat on the left side of the

vehicle, between the engine and fuel tank.

Inspect the separator for leaks. Drain water and replace the separator atdaily

the intervals outlined in the Periodic Maintenance Chart. Service the separator

more frequently if the vehicle is operated with inferior fuel.

CAUTION

Both fuel and water will drain from the separator during the following

procedure. Use caution and observe all fuel safety precautions when handling

fuel.

1. Be sure the engine is at room temperature.

2. Disconnect the battery.

3. Remove the seat.

4. Remove the storage bin.

5. Locate the fuel filter / water separator.

6. Place an appropriate container under the fuel filter area to catch any excess

fuel from the drain valve.

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MAINTENANCE

7. Unscrew the drain value 1/2 to 1 full turn until fuel starts to drain from the

bottom – do NOT unscrew the valve completely.

IMPORTANT

The drain valve has standard threads.

8. Wait for fuel and water to stop draining and then firmly retighten valve.

9. Clean up any excess fuel.

10. Reconnect the battery.

11. Prime the fuel system by turning the ignition switch to the “ON” position for

10–15 seconds.

12. Start the engine and verify that no fuel leaks are present.

13. Reinstall the seat.

FUEL FILTER / WATER SEPARATOR

REPLACEMENT

1. Be sure engine is at room temperature.

2. Remove seat.

3. Remove storage bin.

4. Drain fuel filter / water separator. See .page 137

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MAINTENANCE

5. Unscrew fuel filter / water separatorqfrom the filter mount using a

commercially available filter wrench if not able to remove by hand.

IMPORTANT

The filter has standard threads.

6. Properly drain and dispose of the old fuel filter / water separator.

7. Lightly lubricate the rubber gasket of the fuel filter / water separator withNew

fresh engine oil.

TORQUE

Fuel Filter / Water Separator:

Thread onto the mount until the gasket lightly touches the filter housing.

Tighten an additional 1/2–3/4 turn.

IMPORTANT

Ensure the drain valve on the bottom of the filter is snug and did not loosen up

during filter installation.

8. Clean up any excess fuel.

9. Reconnect battery.

10. Prime fuel system by turning ignition to “ON” position for 10–15 seconds.

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MAINTENANCE

11. Start engine and verify that no fuel leaks are present.

12. Reinstall storage bin and seat.

140

MAINTENANCE

THROTTLE SYSTEM

WARNING

Failure to check or maintain proper operation of the throttle system can result

in an accident and lead to serious injury or death if the throttle pedal sticks

during operation.

Always check the pedal for free movement and return before starting the

engine and occasionally during operation. Never start or operate this vehicle if

it has a sticking or improperly operating throttle pedal. Immediately contact

your dealer for service if throttle problems arise.

THROTTLE FREEPLAY

If the throttle pedal has excessive play due to cable stretch or maladjustment, it

will cause a delay in throttle response, especially at low engine speed. The

throttle may also not open fully. If the throttle pedal has no freeplay, the throttle

may be hard to control, and the idle speed may be erratic.

Check the throttle pedal freeplay at the intervals outlined in the Periodic

Maintenance Chart. Adjust the freeplay if necessary.

THROTTLE FREEPLAY INSPECTION

1. Apply the brakes. Engage the park brake. Shift the transmission to neutral.

2. Remove grass, leaves, foreign matter, and other flammable material or

debris from the throttle linkage and components.

3. Start the engine. Allow it to warm up thoroughly.

4. Measure the distance the throttle pedal moves before the engine begins to

pick up speed. Freeplay should be 1/16–1/8 in (1.6–3.2 mm).

IDLE RPM

Idle RPM is preset by the manufacturer. If the engine idle speed is not

satisfactory, please see your POLARIS dealer for adjustment.

141

MAINTENANCE

THROTTLE CABLE ADJUSTMENT

CABLE ADJUSTMENT

1. Ensure that the throttle cable is properly routed and retained to the unit.

2. On the pedal side, tighten jam nutsq.

TORQUE

Throttle Cable Jam Nut (pedal side): 43 in-lbs (5 N·m)

3. On the engine side, tighten jam nutsw.

TORQUE

Throttle Cable Jam Nut (engine side): 10 ft-lbs (13 N·m)

4. Slide back the protective cover to expose the jam nuteand adjuster

screwr.

5. Loosen the jam nut and turn the adjuster screw until the throttle lever on the

engine moves.

6. Loosen the adjuster back so there is no tension in the cable.

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MAINTENANCE

7. Once properly adjusted, tighten the jam nut against the adjuster and re-install

the protective sleeve.

8. Start the engine and allow if to warm up thoroughly. Measure the distance

the throttle pedal moves before the engine begins to pick up speed. Freeplay

should be 1/16–1/8 in (1.6–3.2 mm).

143

MAINTENANCE

THROTTLE PEDAL ADJUSTMENT

NOTICE

It is ideal to adjust the throttle pedal with the help of an assistant.

1. Loosen the adjustment screw qand jam nut w.

2. With the vehicle off and in park, have the assistant fully depress and hold

down the throttle pedal.

3. The person on the engine side should manually press the lever on the engine

to ensure that full travel is being achieved.

4. Release the pedal and engine lever and adjust the pedal adjustment screw

out 1/2 turn at a time and continue this process until full travel of the engine

lever is obtained.NOT

144

MAINTENANCE

5. Slowly adjust the pedal adjuster in a 1/4 turn at a tie until the full engine

throttle obtained. Once proper adjustment is obtained, tighten jam nut inIS

place to hold the adjustment position.

TORQUE

Throttle Pedal Adjuster Jam Nut: 14 ft-lbs (19 N·m)

6. With the unit in park, start the unit. Ensure the engine idle is still within range

of . Fully depress the throttle pedal and ensure that the1200 +/- 100 RPM

engine RPM gets to .3850 +/- 50 RPM

CAUTION

DO NOT HOLD hold the unit wide open for more than 10 seconds.

145

MAINTENANCE

BRAKES

The front and rear brakes are hydraulic disc type brakes. Press down on the

brake pedal to engage the brakes.

BRAKE FLUID

Inspect the brake system routinely. Inspect the level of the brake fluid before

each operation.

WARNING

After opening a bottle of brake fluid, always discard any unused portion. Never

store or use a partial bottle. Brake fluid is hygroscopic, meaning it rapidly

absorbs moisture from the air. The moisture causes the boiling temperature of

the brake fluid to drop, which can lead to early brake fade and the possibility of

accident or severe injury.

Change the brake fluid every two years and any time the fluid becomes

contaminated, the fluid level is below the minimum, or if the type and brand of

the fluid in the reservoir are unknown.

1. Position the vehicle on a level surface and turn off the engine.

2. View the brake fluid level at the reservoir in the driver’s side wheel well. The

level should be between the upper (MAX) and lower (MIN) level lines.

3. If the fluid level is lower than the upper level line, open the hood and add

brake fluid to the upper (MAX) line.

4. Apply the brake forcefully for a few seconds and check for fluid leakage

around the fittings.

146

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. Check the brake pedal for

excessive travel or a spongy

feel.

3. Check the friction pads for wear,

damage and looseness.

4. Check brake discs for signs of

cracks, excessive corrosion,

warping or other damage. Clean

any grease using an approved

brake cleaner or alcohol.

5. Inspect the brake disc spline and

pad wear surface qfor

excessive wear. Change pads

when worn to 0.040 in (1 mm).

147

MAINTENANCE

PARK BRAKE INSPECTION

1. Apply the service brakes, and pull the park brake lever.

2. While engaging the parking brake lever, verify the following:

• The ratchet teeth should be heard and felt as the locking pawl clicks into

place.

• After a few clicks, the park brake indicator lamp on the instrument cluster

should illuminate.

• The rear wheels of the vehicle should not rotate when turning by hand.

• Ensure that plenty of resistance is felt in the lever's throw before fully

extended to the hard stop.

NOTICE

Average pull force is 50 lbs.

3. When the park brake is fully engaged, the vehicle should not roll while

parked.

4. If park brake fails inspection, contact your dealer for adjustment/repairs.

STEERING INSPECTION

Check the steering for specified freeplay, smooth operation, and inspect the

steering boots at the intervals outlined in the Periodic Maintenance Chart

section.

1. Position the vehicle on level ground.

2. Lightly turn the steering wheel left and right.

3. There should be 0.8-1.0 in (20-25 mm) of freeplay.

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MAINTENANCE

4. If there is excessive free play or strange noises, or the steering feels rough or

“catchy,” have the steering system inspected by an authorized dealer.

5. Inspect boots qfor tears. If a tear is discovered, have the boot replaced by

an authorized dealer.

WHEEL BEARING INSPECTION

1. Elevate front end of machine so front wheels are off the ground.

2. Check for any looseness in front wheel/hub assembly by grasping the tire

firmly at top and bottom first, and then at front and rear. Try to move the

wheel and hub by pushing inward and pulling outward.

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MAINTENANCE

3. If abnormal movement is detected, take the vehicle to your dealer for service.

4. Repeat the procedure for the rear wheels.

AXLE INSPECTION

Inspect inboard and outboard boots on both sides of the vehicle, frontqand

rear w, for tears. If a tear is discovered, have the boot replaced by an authorized

dealer.

150

MAINTENANCE

SPRING ADJUSTMENT (IF APPLICABLE)

Adjust the front and rear shock

absorber springs by rotating the

adjustment cam qeither clockwise

or counterclockwise to increase or

decrease spring tension.

TIRES

WARNING

Operating your vehicle with worn tires will increase the possibility of skidding,

loss of control and an accident, which could result in serious injury or death.

Always replace tires when the tread depth measures 1/8 in (3 mm) or less.

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.

TIRE TREAD DEPTH

Always replace tires when tread depth is worn to 1/8 in (3 mm) or less.

151

MAINTENANCE

WHEEL REMOVAL

1. Position the vehicle on a level surface.

2. Place the transmission in PARK. Stop the engine.

3. Loosen the wheel nuts slightly.

4. Elevate the side of the vehicle by placing a suitable stand under the frame.

5. Remove the wheel nuts and washers. Remove the wheel.

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. Your dealer can assist.

1. Place the transmission in PARK.

2. Place the wheel on the hub with the valve stem toward the outside and

rotation arrows on the tire pointing toward forward rotation.

3. Attach the wheel nuts and washers and finger-tighten.

4. Carefully lower the vehicle to the ground.

5. Torque the wheel nuts to specification.

POWER STEERING UNIT (IF EQUIPPED)

If your model is equipped with

power steering, frequently clean the

areas around and on the power

steering unit to allow proper cooling.

Clean these areas ethoroughly.

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MAINTENANCE

HEADLIGHT BEAM ADJUSTMENT

To adjust the headlight beam, do the following:

1. Place the vehicle on a level surface with the headlight approximately 25 ft

(7.6 m) from a wall.

2. Measure the distance from the floor to the center of the headlight and make a

mark on the wall at the same height.

3. Apply the brakes. Start the engine. Turn on the headlights.

4. Observe the headlight aim. The most intense part of the headlight beam

should be aimed 8 in (20 cm) below the mark placed on the wall. Include the

weight of a rider on the seat while performing this step.

5. If a headlight needs adjustment, locate the adjustment screw at the back of

the headlight.

6. Loosen the screw, adjust the headlight, and tighten the screw.

7. Repeat steps 4-6 until the lamp is properly adjusted.

156

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. The fuse box is located

under the seat, next to the battery

q. Spare fuses are provided in the

fuse box.

If you suspect that a fuse or relay may not be working properly, your dealer can

assist.

FUSE SIZE FEATURE SUPPORTED

70A Glow Plug Relay

40A Glow Plugs

30A Starter Solenoid (4000 models)

30A EPS

20A Starter Solenoid (2000 models)

20A Chassis

20A Accessories

15A Lights

15A EFI (Engine Controller)

10A Charge Receptacle

10A Horn

10A Brakes

10A Fuel Pump

10A Alternator

10A Drive Mode

158

MAINTENANCE

BATTERY

Your vehicle has a sealed battery, which requires little maintenance. Always

keep battery terminals and connections free of corrosion. If cleaning is

necessary, remove the corrosion with a stiff wire brush. Wash with a solution of

one tablespoon baking soda and one cup water. Rinse well with tap water and

dry off with clean shop towels. Coat the terminals with dielectric grease or

petroleum jelly.

BATTERY REMOVAL

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.

1. Remove the storage bin under the passenger seat to access the battery.

2. Disconnect the black (-) battery cable first. Disconnect the red (+) battery

cable last.

3. Remove the battery hold-down strap.

4. Lift the battery out of the vehicle.

BATTERY INSTALLATION

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. Follow the battery

charging instructions before installing the battery.

1. Ensure that the battery is fully charged.

2. Place the fully charged battery in the battery holder. Make sure the positive

terminal is toward the driver’s side of the vehicle.

3. Coat the terminals with dielectric grease or petroleum jelly.

4. Connect and tighten the red (+) cable first. Connect and tighten the black (-)

cable last.

5. Install the hold-down strap.

6. Reinstall the storage bin and seat.

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MAINTENANCE

BATTERY STORAGE

Whenever the vehicle is not used for a period of three months or more, remove

the battery from the vehicle, ensure that it's fully charged, and store it out of the

sun in a cool, dry place. Check battery voltage each month during storage and

recharge as needed to maintain a full charge.

TIP

Battery charge can be maintained by using a POLARIS Battery Tender charger

or by charging about once a month to make up for normal self discharge.

Battery Tender can be left connected during the storage period, and will

automatically charge the battery if the voltage drops below a predetermined

point. See the Polaris Products section for the part numbers.

BATTERY CHARGING

The following battery charging instructions apply only to the installation of a

sealed battery. Read all instructions before proceeding with the installation of

this battery.

The sealed battery is already filled with electrolyte and has been sealed and fully

charged at the factory. pry the sealing strip off or add any other fluid to thisNever

battery.

The single most important thing about maintaining a sealed battery is to keep it

fully charged. Since the battery is sealed and the sealing strip cannot be

removed, you must use a voltmeter or multimeter to measure DC voltage.

WARNING

An overheated battery may explode, causing severe injury or death. Always

watch charging times carefully. Stop charging if the battery becomes very

warm to the touch. Allow it to cool before resuming charging.

For a refresh charge, follow all instructions carefully.

1. Check the battery voltage with a voltmeter or multimeter. A fully charged

battery will register 12.8 V or higher.

2. If the voltage is less than 12.8 volts, recharge the battery at 1.2 amps or less

until battery voltage is 12.8 or greater.

3. When using an automatic charger, refer to the charger manufacturer's

instructions for recharging. When using a constant current charger, use the

guidelines below for recharging.

Always verify battery condition before and 1-2 hours after the end of charging.

160

MAINTENANCE

CLEANING AND STORAGE

WASHING THE VEHICLE

Keeping your POLARIS vehicle clean will not only improve its appearance but it

can also extend the life of various components.

NOTICE

High water pressure may damage components. POLARIS recommends

washing the vehicle by hand or with a garden hose, using mild soap.

NOTICE

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.

1. Use a professional-type washing cloth, cleaning the upper body first and the

lower parts last.

2. Rinse with clean water frequently.

3. Dry surfaces with a chamois to prevent water spots.

WASHING TIPS

• Avoid the use of harsh cleaners, which can scratch the finish.

• Do not use a power washer to clean the vehicle.

• Do not use medium to heavy duty compounds on the finish.

• 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.

• Grease all zerk fittings immediately after washing. Allow the engine to run for

a while to evaporate any water that may have entered the engine or exhaust

system.

If a high pressure water system is used for cleaning (not recommended),

exercise extreme caution. The water may damage components and could

remove paint and labels. Avoid directing the water stream at the following items:

• Wheel bearings

• Radiator

• Transmission seals

• Brakes

• Cab and body panels

• Labels and decals

• Electrical components and wiring

• Air intake components

162

MAINTENANCE

If an informational or graphic label becomes illegible or comes off, contact your

POLARIS dealer, or other qualified person, to purchase a replacement.

Replacement safety labels are provided by POLARIS at no charge.

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.

POLISHING TIPS

• Avoid the use of automotive products, some of which can scratch the finish of

your vehicle.

• 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.

STORAGE TIPS

NOTICE

Starting the engine during the storage period will disturb the protective film

created by fogging and damage could occur. Never start the engine during the

storage period.

CLEAN THE EXTERIOR

Make any necessary repairs and clean the vehicle as recommended.

OIL AND FILTER

Change the oil and filter. See the Engine Oil section.

AIR FILTER / AIR BOX

Replace the air filter. See Maintenance Chapter. Clean the air box.

FLUID LEVELS

Inspect the fluid levels. Add or change fluids as recommended in the Periodic

Maintenance Chart.

• Demand drive fluid (front gearcase)

• Rear gearcase fluid (if equipped)

• Transmission fluid

• Brake fluid (change every two years and any time the fluid looks dark or

contaminated)

• Coolant (test strength/fill)

163

MAINTENANCE

INSPECT AND LUBRICATE

Inspect all cables and lubricate all areas of the vehicle as recommended in the

Periodic Maintenance Chart.

STORAGE AREA / COVERS

Be sure the storage area is well ventilated. Cover the vehicle with a genuine

POLARIS cover. Do not use plastic or coated materials. They do not allow

enough ventilation to prevent condensation, and may promote corrosion and

oxidation.

REMOVAL FROM STORAGE

1. Charge the battery if necessary. Install it in the vehicle.

2. Fill the fuel tank with fuel.

3. Check all the points listed in the Daily Pre-Ride Inspection section. Tightness

of the bolts, nuts and other fasteners should be checked by an authorized

POLARIS dealer.

4. Lubricate at the intervals outlined in the Periodic Maintenance Chart.

164

MAINTENANCE

TOWING A PRO XD

Towing this vehicle is not recommended. Always transport the vehicle on a

trailer or flatbed with all four wheels off the ground.

If towing a disabled vehicle is unavoidable, place the disabled vehicle’s

transmission in neutral. Tow the shortest distance possible. Do not operate

faster than 10 mph (16 km/h).

166

MAINTENANCE

SPECIFICATIONS

2000D

POLARIS PRO XD 2000D

Maximum Weight

Capacity

2000D AWD: 1900 lb (862 kg) (including operator,

passenger, cargo, accessories)

Dry Weight 2000D AWD: 1665 lb (755 kg)

GVWR – Gross

Vehicle Weight

Rating

2000D AWD: 3600 lb (1633 kg) per ANSI/OPEI

B71.9-2016, Section 5.1.2

Fuel Capacity 11.5 gal (43.5 L)

Engine Oil Capacity 3.9 qt (3.7 L)

Coolant Capacity 5.8 qt (5.5 L)

Towing Capacity 2500 lb (1134 kg)

Hitch Tongue

Capacity

250 lb (113 kg)

Max. Cargo Box Load 1250 lb (567 kg)

Overall Length 126 in (320 cm)

Overall Width 62.5 in (158.8 cm)

Overall Height 75 in (191 cm)

Wheelbase 85 in (215.9 cm)

Cargo Box

Dimensions (Inside)

54 in (137 cm) wide, 43.5 in (110 cm) long, 11.5 in

(29 cm) high

Ground Clearance 11 in (27.9 cm)

Min. Turning Radius 112 in (284.5 cm)

Engine Kubota liquid-cooled 3 cylinder diesel

Displacement 898 cc

Bore x Stroke 72 mm x 73.6mm

Alternator Output 12V DC 140A

167

SPECIFICATIONS

POLARIS PRO XD 2000D

Compression Ratio 22.8:1

Starting System Electric

Fuel System Mechanical fuel injection

Front Suspension Dual A-arm w/9 in (22.86 cm) of travel

Rear Suspension Independent w/9 in (22.86 cm) of travel

Lubrication System Full pressure with full flow filter

Driving System Type PVT, 4-wheel independent shaft, lockable differential

Shift Type Single Lever (H/L/N/R/P)

Transmission Gear

Ratio - High

Front 5.17:1 / Rear 15.45:1

Transmission Gear

Ratio - Low

Front 9.65:1/ Rear 28.84:1

Transmission Gear

Ratio - Reverse

Front 9.16:1 / Rear 27.39:1

Front Drive Ratio 3.82:1

Tire Size - Front 26 x 10 - 12

Tire Size - Rear 26 x 10 - 12

Tire Pressure - Front 24 psi (165 kPa)

Tire Pressure - Rear 24 psi (165 kPa)

Brakes, Front/Rear Foot Activated, 4 wheel hydraulic disc

Hood Headlight 2 single beam, 50W, quartz/halogen

Taillights 10 L.E.D. (.28W)

Brake Light 10 L.E.D. (3.1W)

168

SPECIFICATIONS

4000D

POLARIS PRO XD 4000D

Maximum Weight

Capacity

2075 lb (941 kg) (including operator, passengers,

cargo, accessories)

Dry Weight 1925 lb (873 kg)

GVWR – Gross

Vehicle Weight

Rating

4000 lb (1814 kg) per ANSI/OPEI B71.9-2016,

Section 5.1.2

Fuel Capacity 11.5 gal (43.5 L)

Engine Oil Capacity 3.9 qt (3.7 L)

Coolant Capacity 6.6 qt (6.25 L)

Towing Capacity 2500 lb (1134 kg)

Hitch Tongue

Capacity

250 lb (113 kg)

Max. Cargo Box Load 1250 lb (567 kg)

Overall Length 157 in (399 cm)

Overall Width 62.5 in (158.8 cm)

Overall Height 75 in (191 cm)

Wheelbase 117 in (297 cm)

Cargo Box

Dimensions (Inside)

54 in (137 cm) wide, 43.5 in (110 cm) long, 11.5 in

(29 cm) high

Ground Clearance 11 in (27.9 cm)

Min. Turning Radius 154 in (391.2 cm)

Engine Kubota liquid-cooled 3 cylinder diesel

Displacement 898 cc

Bore x Stroke 72 mm x 73.6mm

Alternator Output 12V DC 140A

Compression Ratio 22.8:1

169

SPECIFICATIONS

WARRANTY

LIMITED WARRANTY

POLARIS Inc., 2100 Highway 55, Medina, MN 55340 (POLARIS) gives a TWO

YEAR LIMITED WARRANTY on all components of your POLARIS vehicle

against defects in material or workmanship. POLARIS further warrants that the

spark arrester in this product will meet the efficiency requirements of USFS

standard 5100-1C for at least 1000 hours when subjected to normal use and

when maintenance and installation are in accordance with POLARIS

recommendations.

This warranty covers parts and labor charges for repair or replacement of

defective parts and begins on the date of purchase by the original retail

purchaser. This warranty is transferable to another owner during the warranty

period through a POLARIS dealer, but any such transfer will not extend the

original term of the warranty. The duration of this warranty may vary by

international region based upon local laws and regulations.

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. If you have

not signed the original registration and received the customer copy, please

contact your dealer immediately. NO WARRANTY COVERAGE WILL BE

ALLOWED UNLESS YOUR VEHICLE IS REGISTERED WITH POLARIS. Initial

dealer preparation and set-up of your vehicle is very important in ensuring

trouble-free operation. Purchasing a machine in the crate or without proper

dealer set-up will void your warranty coverage.

177

WARRANTY

HOW TO OBTAIN WARRANTY SERVICE

If your vehicle requires warranty service, you must take it to a POLARIS

Servicing Dealer. When requesting warranty service you must present your copy

of the Warranty Registration Form to the dealer. (THE COST OF

TRANSPORTATION TO AND FROM THE DEALER IS YOUR

RESPONSIBILITY.) POLARIS suggests that you use your original selling dealer;

however, you may use any POLARIS Servicing Dealer to perform warranty

service.

IN THE COUNTRY WHERE YOUR PRODUCT WAS

PURCHASED:

Warranty or Service Bulletin repairs must be done by an authorized POLARIS

dealer, or other qualified person. If you move or are traveling within the country

where your product was purchased, Warranty and Service Bulletin repairs may

be requested from any authorized POLARIS dealer, or other qualified person,

that sells the same line as your product.

OUTSIDE THE COUNTRY WHERE YOUR PRODUCT

WAS PURCHASED:

If you are traveling temporarily outside the country where your product was

purchased, you should take your product to an authorized POLARIS dealer, or

other qualified person. You must show the dealer photo identification from the

country of the selling dealer's authorized location as proof of residence. Upon

residence verification, the servicing dealer will be authorized to perform the

warranty repair.

IF YOU MOVE:

If you move to another country, be sure to contact POLARIS Customer

Assistance and the customs department of the destination country before you

move. Product importation rules vary considerably from country to country. You

may be required to present documentation of your move to POLARIS in order to

continue your warranty coverage. You may also be required to obtain

documentation from POLARIS in order to register your product in your new

country. You should warranty register your product at a local POLARIS dealer in

your new country immediately after you move to continue your warranty

coverage and to ensure that you receive information and notices regarding your

product.

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.

180

WARRANTY

The emissions warranty period for all other engine not already listed is 3000

hours of operation or five (5) years of use, whichever first occurs.

2. For marine engines (commercial Category 1)

The emissions warranty period for all engines rated under 19kW (25 Hp) is 1500

hours of operation or two and a half (2.5) years of use, whichever first occurs.

The emissions warranty period for all engines rated at or above 19 kW (25 Hp)

and under 37kW (50 Hp) is 2500 hours of operation or three and a half (3.5)

years of use, whichever first occurs.

The emissions warranty period for all engines rated at or above 37kW (50 Hp) is

5000 hours of operation or five (5) years of use, whichever first occurs.

OWNER’S WARRANTY RESPONSIBILITIES

(a) As the engine owner, you are responsible for the performance of the required

maintenance listed in your KUBOTA operator’s manual. KUBOTA recommends

that you retain all receipts covering maintenance on your engine, but KUBOTA

cannot deny a warranty claim solely for the lack of receipts or for your failure to

ensure the performance of all scheduled maintenance.

(b) As the engine owner, you should be aware, however, that KUBOTA may

deny your warranty coverage if your engine or a part has failed due to abuse,

vandalism, neglect, improper maintenance or unapproved modifications.

of any other fuel may result in your engine no longer operating in compliance

with Federal or California’s emissions requirements.

(d) You are responsible for presenting your engine to the nearest dealer or

service station authorized by KUBOTA when a problem exists. The warranty

repairs should be completed in a reasonable amount of time, not to exceed 30

days.

(e) If you have any questions regarding your warranty rights and responsibilities

or the location of the nearest authorized dealer or distributor, you should contact:

KUBOTA ENGINE AMERICA CORPORATION, Service Department at 1-800-

532-9808, kea_g.eewri@kubota.com or KUBOTA TRACTOR CORPORATION,

National Service Department at 1-800-558-2682,

KubotaEmissionsWarranty@kubota.com or KUBOTA CANADA LTD at (905)

294-7477.

COVERAGE

KUBOTA warrants to the initial purchaser and each subsequent purchaser that

your engine will be designed, built and equipped, at the time of sale, to meet all

applicable regulations. KUBOTA also warrants to the initial purchaser and each

subsequent purchaser that your engine shall be free from defects in materials

and workmanship which cause the engine to fail to conform to applicable

regulations for the period mentioned above from the original date of sale.

183

WARRANTY

KUBOTA shall remedy warranty defects at any authorized KUBOTA engine

dealer or warranty station. Any authorized work done at an authorized dealer or

warranty station shall be free of charge to the owner if such work determines

that a warranted part is defective. Any KUBOTA approved or equivalent

replacement part (including any KUBOTA approved aftermarket part) may be

used for any warranty maintenance or repairs on emission related parts, and

must be provided free of charge to the owner if the part is still under warranty.

KUBOTA is liable for damages to other engine components caused by the

failure of a warranted part still under warranty. The use of replacement parts not

equivalent to the original parts may impair the effectiveness of your engine

emission control system. If such a replacement part is used in the repair or

maintenance of your engine, and KUBOTA determines it is defective or causes a

failure of a warranted part, your claim for repair of your engine may be denied.

Listed below are the parts covered by the Federal and California Emission

Control Systems Warranty. Some parts listed below may require scheduled

maintenance and are warranted up to the first scheduled replacement point for

that part. The warranted parts are (if applicable):

1. Air-Induction System

a. Intake Manifold

b. Turbocharger System

c. Charge Air Cooling System (Intercooler)

2. Catalyst or Thermal Reactor System

a. Catalytic converter

b. Exhaust manifold

3. Fuel Injection System

a. Fuel Supply Pump (Common Rail System)

b. Injector

c. Injection Pipe

d. Common Rail

e. Smoke Puff Limiter

f. Speed Timer

g. Cold Advance Timer

h. Injection Pump

4. Electronic Control System

a. ECU

184

WARRANTY

Produkt Specifikationer

Mærke:	Polaris
Kategori:	Ikke kategoriseret
Model:	Pro XD 4000D AWD (2021)

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