Owners Manual
Page 35
... OFF Fuel Tank Cap Fuel Tank Cap This vehicle is located under the electrical access panel. Refuel when the gauge indicates a low fuel condition. Do not use fuel with the engine stopped, and outdoors or in starting . Fuel Valve Choke The choke assists in a well ventilated area. FEATURES AND CONTROLS Fuel Valve The fuel valve is equipped with a minimum pump octane number of operation, or annually. Refuel on page 46 for correct choke and throttle...
... OFF Fuel Tank Cap Fuel Tank Cap This vehicle is located under the electrical access panel. Refuel when the gauge indicates a low fuel condition. Do not use fuel with the engine stopped, and outdoors or in starting . Fuel Valve Choke The choke assists in a well ventilated area. FEATURES AND CONTROLS Fuel Valve The fuel valve is equipped with a minimum pump octane number of operation, or annually. Refuel on page 46 for correct choke and throttle...
Owners Manual
Page 36
... miles per hour for extended periods and when operating uphill at a slow speed. 32 Gear Selector NOTICE: Shifting gears with the engine speed above idle or while the vehicle is left unattended, always place the transmission in PARK and lock the parking brake. H: High Gear L: Low Gear N: Neutral R: Reverse P: Park To shift gears, brake to the desired gear. When the engine is located on the right side of the vehicle. FEATURES AND CONTROLS Automatic Transmission Gear Selector The transmission gear selector is idling...
... miles per hour for extended periods and when operating uphill at a slow speed. 32 Gear Selector NOTICE: Shifting gears with the engine speed above idle or while the vehicle is left unattended, always place the transmission in PARK and lock the parking brake. H: High Gear L: Low Gear N: Neutral R: Reverse P: Park To shift gears, brake to the desired gear. When the engine is located on the right side of the vehicle. FEATURES AND CONTROLS Automatic Transmission Gear Selector The transmission gear selector is idling...
Owners Manual
Page 37
... the rear wheels regain traction. FEATURES AND CONTROLS All Wheel Drive (AWD) System The All Wheel Drive system is on or off . When the switch is no limit to AWD. 33 There is on . If the rear wheels are spinning, release the throttle before getting into conditions where front wheel drive may be needed. Tip: The override switch allows activation of time the vehicle may remain in AWD, the demand drive unit will automatically...
... the rear wheels regain traction. FEATURES AND CONTROLS All Wheel Drive (AWD) System The All Wheel Drive system is on or off . When the switch is no limit to AWD. 33 There is on . If the rear wheels are spinning, release the throttle before getting into conditions where front wheel drive may be needed. Tip: The override switch allows activation of time the vehicle may remain in AWD, the demand drive unit will automatically...
Owners Manual
Page 39
..., a battery over-voltage may have occurred and the instrument cluster may also occur when the engine is at idle and high electrical load (lights, cooling fan, accessories) is applied. Refuel immediately. 8. Check Engine Warning Indicator - When the last segment clears, a low fuel warning is in the instrument cluster. If the instrument cluster fails to your POLARIS dealer for 2.5 seconds at start-up for proper diagnosis. 1. AWD Indicator - FEATURES AND CONTROLS Instrument Cluster Rider Information Center The...
..., a battery over-voltage may have occurred and the instrument cluster may also occur when the engine is at idle and high electrical load (lights, cooling fan, accessories) is applied. Refuel immediately. 8. Check Engine Warning Indicator - When the last segment clears, a low fuel warning is in the instrument cluster. If the instrument cluster fails to your POLARIS dealer for 2.5 seconds at start-up for proper diagnosis. 1. AWD Indicator - FEATURES AND CONTROLS Instrument Cluster Rider Information Center The...
Owners Manual
Page 46
... sustained idle. 5. Avoid aggressive acceleration and high speed operation during the break-in period, change both the oil and the filter at 20 hours or one month. Vary the throttle positions. Always exercise extreme caution whenever handling gasoline. 2. See page 31. See page 45. 6. PVT Break-in (Clutches/Belt) A proper break-in period. 42 OPERATION Break-In Period Engine and...
... sustained idle. 5. Avoid aggressive acceleration and high speed operation during the break-in period, change both the oil and the filter at 20 hours or one month. Vary the throttle positions. Always exercise extreme caution whenever handling gasoline. 2. See page 31. See page 45. 6. PVT Break-in (Clutches/Belt) A proper break-in period. 42 OPERATION Break-In Period Engine and...
Owners Manual
Page 62
... Cargo WARNING Overloading the vehicle or carrying or towing cargo improperly can alter vehicle handling and may cause loss of control or brake instability, which can create unstable operating conditions, which could result in loss of control of the vehicle. NEVER EXCEED THE MAXIMUM WEIGHT CAPACITY of vehicle overturn. CARGO WEIGHT DISTRIBUTION should never exceed 10 mph (16 kph) while towing a load on the rear rack. Carrying...
... Cargo WARNING Overloading the vehicle or carrying or towing cargo improperly can alter vehicle handling and may cause loss of control or brake instability, which can create unstable operating conditions, which could result in loss of control of the vehicle. NEVER EXCEED THE MAXIMUM WEIGHT CAPACITY of vehicle overturn. CARGO WEIGHT DISTRIBUTION should never exceed 10 mph (16 kph) while towing a load on the rear rack. Carrying...
Owners Manual
Page 63
... terrain, reduce speed and cargo weight to the hitch point. Use low forward gear when hauling or towing heavy cargo to extend belt life. 2/3 1/3 Towing Loads Always attach a towed load to maintain stable driving conditions. Remove the hitch from the ATV when not towing a trailer. Never install automotive accessories on hitch) must not exceed the maximum weight capacity of rear rack cargo weight and tongue weight must not exceed the rear rack capacity. • The...
... terrain, reduce speed and cargo weight to the hitch point. Use low forward gear when hauling or towing heavy cargo to extend belt life. 2/3 1/3 Towing Loads Always attach a towed load to maintain stable driving conditions. Remove the hitch from the ATV when not towing a trailer. Never install automotive accessories on hitch) must not exceed the maximum weight capacity of rear rack cargo weight and tongue weight must not exceed the rear rack capacity. • The...
Owners Manual
Page 69
...; Radiator (if applicable) Cooling hoses (if applicable) Engine mounts Exhaust muffler/ pipe E E Spark plug Ignition timing 100 H 100 H 100 H 100 H 100 H 100 H 100 H 12 M 12 M 12 M 12 M 12 M 12 M 12 M Wiring 65 replace as needed 50 H 50 H 50 H 50 H 50 H 50 H 50 H 3M 6M 6M 6M 6M 6M 6M E E Carburetor air intake ducts/flange Drive belt Cooling system Engine oil change Oil filter change at tank cap, lines, fuel valve, filter, pump, carburetor; pressure...
...; Radiator (if applicable) Cooling hoses (if applicable) Engine mounts Exhaust muffler/ pipe E E Spark plug Ignition timing 100 H 100 H 100 H 100 H 100 H 100 H 100 H 12 M 12 M 12 M 12 M 12 M 12 M 12 M Wiring 65 replace as needed 50 H 50 H 50 H 50 H 50 H 50 H 50 H 3M 6M 6M 6M 6M 6M 6M E E Carburetor air intake ducts/flange Drive belt Cooling system Engine oil change Oil filter change at tank cap, lines, fuel valve, filter, pump, carburetor; pressure...
Owners Manual
Page 86
... the wheel on the hub with the valve stem toward the outside and rotation arrows on the tire pointing toward forward rotation. 4. WARNING! Nut Type Lug Nut (Aluminum Wheels) Nut Torque 30 ft. Loose nuts could cause a tire to specification. Lock the parking brake. 3. Wheel Nut Torque Specifications Check the wheel nut torques occasionally and when they've been loosened for maintenance service. Torque the wheel nuts...
... the wheel on the hub with the valve stem toward the outside and rotation arrows on the tire pointing toward forward rotation. 4. WARNING! Nut Type Lug Nut (Aluminum Wheels) Nut Torque 30 ft. Loose nuts could cause a tire to specification. Lock the parking brake. 3. Wheel Nut Torque Specifications Check the wheel nut torques occasionally and when they've been loosened for maintenance service. Torque the wheel nuts...
Owners Manual
Page 90
Clean lights frequently and replace burned out lamps promptly. CAUTION! MAINTENANCE Lights Poor lighting can cause burns to remove it. 7. Always make sure lights are adjusted properly for best visibility. Headlight Lamp Replacement When servicing a halogen lamp, don't touch the lamp with bare fingers. Remove the two screws on the wiring. 6. Lift the pod slightly while depressing the tabs at the rear of...
Clean lights frequently and replace burned out lamps promptly. CAUTION! MAINTENANCE Lights Poor lighting can cause burns to remove it. 7. Always make sure lights are adjusted properly for best visibility. Headlight Lamp Replacement When servicing a halogen lamp, don't touch the lamp with bare fingers. Remove the two screws on the wiring. 6. Lift the pod slightly while depressing the tabs at the rear of...
Owners Manual
Page 91
Measure the distance from a wall. Start the engine.Turn the headlight switch to the desired position by turning the knob either clockwise or counter-clockwise. Include rider weight on the wall. Adjust the beam to high beam. 4. The ...vehicle on a level surface with the headlight approximately 25 ft. (7.6 m) from the floor to make a mark on the wall at the rear of the headlight pod. Tighten the screw. Use the following procedure to the center of the headlight beam should be adjusted slightly upward or downward. 1. MAINTENANCE Lights High Beam Adjustment The headlight...
Measure the distance from a wall. Start the engine.Turn the headlight switch to the desired position by turning the knob either clockwise or counter-clockwise. Include rider weight on the wall. Adjust the beam to high beam. 4. The ...vehicle on a level surface with the headlight approximately 25 ft. (7.6 m) from the floor to make a mark on the wall at the rear of the headlight pod. Tighten the screw. Use the following procedure to the center of the headlight beam should be adjusted slightly upward or downward. 1. MAINTENANCE Lights High Beam Adjustment The headlight...
Owners Manual
Page 92
... the two screws on the lower front corners of the pod. 9. Carefully pull the assembly up and out of the headlight pod. 2. Lift the pod slightly while depressing the tabs at the rear of the adjustment knob stop is 5 1/8" (13 cm). 10. MAINTENANCE Lights Headlight Housing Replacement 1. The distance from the headlamp parting line to release it from the headlight mounting tabs. 6.
... the two screws on the lower front corners of the pod. 9. Carefully pull the assembly up and out of the headlight pod. 2. Lift the pod slightly while depressing the tabs at the rear of the adjustment knob stop is 5 1/8" (13 cm). 10. MAINTENANCE Lights Headlight Housing Replacement 1. The distance from the headlamp parting line to release it from the headlight mounting tabs. 6.
Owners Manual
Page 93
MAINTENANCE Lights Lower Headlamp Replacement 1. Turn the lamp counter-clockwise to the socket and install the new Lamp lamp. 4. Test the light for proper operation. 89 Apply dielectric grease to remove it. 3. Remove the harness connector Connector from the back of the headlight harness counter-clockwise and pull the harness assembly away from the headlight assembly. 2. Remove the headlamp and install the new headlamp...
MAINTENANCE Lights Lower Headlamp Replacement 1. Turn the lamp counter-clockwise to the socket and install the new Lamp lamp. 4. Test the light for proper operation. 89 Apply dielectric grease to remove it. 3. Remove the harness connector Connector from the back of the headlight harness counter-clockwise and pull the harness assembly away from the headlight assembly. 2. Remove the headlamp and install the new headlamp...
Owners Manual
Page 111
... Washing the Vehicle If a high pressure water system is used for polishing the finish on the container. The water may damage components and could remove paint and decals. Avoid directing the water stream at no charge. Replacement safety labels are provided by POLARIS at the following items: • Wheel bearings • Radiator • Transmission seals • Brakes • Cab and body panels • Electrical components • Switches and controls •...
... Washing the Vehicle If a high pressure water system is used for polishing the finish on the container. The water may damage components and could remove paint and decals. Avoid directing the water stream at no charge. Replacement safety labels are provided by POLARIS at the following items: • Wheel bearings • Radiator • Transmission seals • Brakes • Cab and body panels • Electrical components • Switches and controls •...
Owners Manual
Page 114
... the spark plug cap. Apply dielectric grease to specification. 4. Remove the spark plug. Oil will be completely drained of the machine so the engine is level or tilted slightly rearward. 2. Turn the engine over several times. Add or change fluids as recommended in the Periodic Maintenance Chart beginning on page 62. • Demand drive unit (front gearcase) • Rear gearcase (if equipped) • Transmission • Brake fluid (change every two...
... the spark plug cap. Apply dielectric grease to specification. 4. Remove the spark plug. Oil will be completely drained of the machine so the engine is level or tilted slightly rearward. 2. Turn the engine over several times. Add or change fluids as recommended in the Periodic Maintenance Chart beginning on page 62. • Demand drive unit (front gearcase) • Rear gearcase (if equipped) • Transmission • Brake fluid (change every two...
Owners Manual
Page 117
See page 96. Excessive throttle may cause loss of control and vehicle overturn. Drive at a higher speed or use fast, objects from failure to engage clutch. RPM/low ground speed Utility use fast, aggressive throttle application to 7 times. Poor engine performance Check for or snow ingestion into the damage if repeated leaking occurs. Wrong or missing belt Install the recommended belt. Improper break-in Always break...
See page 96. Excessive throttle may cause loss of control and vehicle overturn. Drive at a higher speed or use fast, objects from failure to engage clutch. RPM/low ground speed Utility use fast, aggressive throttle application to 7 times. Poor engine performance Check for or snow ingestion into the damage if repeated leaking occurs. Wrong or missing belt Install the recommended belt. Improper break-in Always break...
Owners Manual
Page 122
Gross Vehicle Weight Maximum Weight Capacity Dry Weight Fuel Capacity Engine Oil Capacity Transmission Oil Capacity Demand Drive Fluid Capacity Coolant Capacity Front Rack/Box Capacity Rear Rack/Box Capacity Receiver Hitch Tongue Capacity Hitch Towing Rating Unbraked Trailer Towing Capacity* Overall Length/Width/Height Wheelbase Ground Clearance Minimum Turning Radius Engine Displacement Bore x Stroke Alternator Output Compression Ratio Carburetor Pilot Jet Main Jet Needle Jet Jet Needle Pilot Screw Ignition System Ignition Timing Spark Plug / Gap Lubrication System Driving System Type Front ...
Gross Vehicle Weight Maximum Weight Capacity Dry Weight Fuel Capacity Engine Oil Capacity Transmission Oil Capacity Demand Drive Fluid Capacity Coolant Capacity Front Rack/Box Capacity Rear Rack/Box Capacity Receiver Hitch Tongue Capacity Hitch Towing Rating Unbraked Trailer Towing Capacity* Overall Length/Width/Height Wheelbase Ground Clearance Minimum Turning Radius Engine Displacement Bore x Stroke Alternator Output Compression Ratio Carburetor Pilot Jet Main Jet Needle Jet Jet Needle Pilot Screw Ignition System Ignition Timing Spark Plug / Gap Lubrication System Driving System Type Front ...
Owners Manual
Page 124
... SPORTSMAN 500 HO SPORTSMAN 500 HO TOURING SPORTSMAN 550 EFI SPORTSMAN 550 X2 SPORTSMAN 550 TOURING SPORTSMAN 800 SPORTSMAN 800 6X6 SPORTSMAN 850 EFI SPORTSMAN 850 X2 SPORTSMAN 850 TOURING RANGER 400 / 450 RANGER 500 4X4 RANGER 800 EFI 4X4 RANGER 500 CREW RANGER 800 EFI CREW RANGER 800 6X6 RANGER HD 800 4X4 RANGER DIESEL RANGER DIESEL CREW RANGER RZR / RZR S RANGER RZR 4 MODEL YEARS 2008, 2009, 2010, 2011...
... SPORTSMAN 500 HO SPORTSMAN 500 HO TOURING SPORTSMAN 550 EFI SPORTSMAN 550 X2 SPORTSMAN 550 TOURING SPORTSMAN 800 SPORTSMAN 800 6X6 SPORTSMAN 850 EFI SPORTSMAN 850 X2 SPORTSMAN 850 TOURING RANGER 400 / 450 RANGER 500 4X4 RANGER 800 EFI 4X4 RANGER 500 CREW RANGER 800 EFI CREW RANGER 800 6X6 RANGER HD 800 4X4 RANGER DIESEL RANGER DIESEL CREW RANGER RZR / RZR S RANGER RZR 4 MODEL YEARS 2008, 2009, 2010, 2011...
Owners Manual
Page 131
... vehicle owner. POLARIS warrants that would cause it is first purchased, this emissions-certified vehicle starts on the date the vehicle is to the following systems: • Air-induction system • Fuel system • Ignition system • Exhaust gas recirculation systems The following parts are also considered emission-related components for exhaust emissions: • Aftertreatment devices • Crankcase ventilation valves • Sensors • Electronic control...
... vehicle owner. POLARIS warrants that would cause it is first purchased, this emissions-certified vehicle starts on the date the vehicle is to the following systems: • Air-induction system • Fuel system • Ignition system • Exhaust gas recirculation systems The following parts are also considered emission-related components for exhaust emissions: • Aftertreatment devices • Crankcase ventilation valves • Sensors • Electronic control...
Owners Manual
Page 135
... Protection...9 C Camber Adjustment ...103 Carburetor ...104 Carburetor Adjustment ...104 Cargo...58-59 Caster Adjustment...103 Choke ...31 Chrome Wheel Care ...108 Cleaning and Storage ...106-111 Clothing ...9 Clutching Chart...119 Consumer Product Safety ...7 F Fluid, Brake ...28, 30 Fluid, Demand Drive ...74-75 Fluid Change, Demand Drive ...75 Foot Brake, Auxiliary ...30 Footwell Removal...80 Fuel Filter ...31 Fuel Recommendations ...31 Fuel Safety ...11 Fuel Tank Cap...31 Fuel Valve...31 Fuse Replacement ...85 131
... Protection...9 C Camber Adjustment ...103 Carburetor ...104 Carburetor Adjustment ...104 Cargo...58-59 Caster Adjustment...103 Choke ...31 Chrome Wheel Care ...108 Cleaning and Storage ...106-111 Clothing ...9 Clutching Chart...119 Consumer Product Safety ...7 F Fluid, Brake ...28, 30 Fluid, Demand Drive ...74-75 Fluid Change, Demand Drive ...75 Foot Brake, Auxiliary ...30 Footwell Removal...80 Fuel Filter ...31 Fuel Recommendations ...31 Fuel Safety ...11 Fuel Tank Cap...31 Fuel Valve...31 Fuse Replacement ...85 131