2022 GENERAL XP 1000 Owner's Manual

Under certain operating conditions, heat generated by the engine and exhaust system can elevate temperatures in the rider 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.

• 1 Helmet

• 2 Eye Protection

• 3 Long Sleeves

• 4 Gloves

• 5 Long Pants

• 6 Over-the-Ankle Boots

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

Parents and supervising adults should verify that young operators have a helmet that fits, and should obtain one of proper size if it does not fit before allowing operation.

• Approved helmets in the USA and Canada bear a U.S. Department of Transportation (DOT) label.

  

• Approved helmets in Europe, Asia and Oceania bear the ECE 22.05 label. The ECE mark consists of a circle surrounding the letter E, followed by the distinguishing number of the country which has granted approval. The approval number and serial number will also be displayed on the label.

  

Do not depend on eyeglasses or sunglasses for eye protection. Whenever riding this POLARIS vehicle, always wear shatterproof goggles or use a shatterproof helmet face shield. POLARIS recommends wearing approved Personal Protective Equipment (PPE) bearing markings such as VESC 8, V-8, Z87.1, or CE. Make sure protective eye wear is kept clean.

Wear gloves for comfort and for protection from sun, cold weather and other elements.

Wear sturdy over-the-ankle boots for support and protection. Never ride a POLARIS vehicle with bare feet or sandals.

Wear long sleeves and long pants to protect arms and legs.

The Proper Use Warning 1 is located on the center console.

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

The Payload/Shift Caution safety label is located on the center console.

WARNING

CAUTION

To avoid transmission damage, shift only when vehicle is stationary and at idle. When vehicle is stopped, place shift in parked position.

WARNING

Improper vehicle use can result in SEVERE INJURY or DEATH

BE PREPARED

• Fasten seat belts.

• Wear an approved helmet and protective gear.

• ALWAYS use cab nets and/or doors.

• Each rider must be able to sit with back against seat, feet flat on the floor, and hands on steering wheel or hand holds. Stay completely inside the vehicle.

Drive Responsibly

Avoid loss of control and rollovers:

• Avoid abrupt maneuvers, sideways sliding, skidding or fishtailing, and never do donuts.

• Slow down before entering a turn.

• Avoid hard acceleration when turning, even from a stop.

• Plan for hills, rough terrain, ruts and other changes in traction and terrain. Avoid paved surfaces.

• Avoid sidehilling (riding across slopes).

Be Sure Riders Pay Attention and Plan Ahead

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

• Keep a firm grip on the steering wheel or hand holds 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.

The Fuel Transport Warning is located in the cargo box.

WARNING

NEVER carry fuel or other flammable liquids on this vehicle. Failure to follow this instruction could lead to serious burn injuries or death.

• The clutch cover warning 1 is located on the clutch cover.

• WARNING

• Improper service or maintenance of this PVT system can result in vehicle damage, SEVERE INJURY or DEATH.

• Always look for and remove debris inside and around clutch and vent system when replacing belt.

• Read owner’s manual or see authorized POLARIS dealer.

CAUTION

Use a Polaris approved air filter. The use of a non-Polaris approved air filter may cause engine damage. Before installing filter, ensure there is no dirt or debris in the clean side of the intake tube. The air filter must be properly seated before the lid is reinstalled. Please reference your owner’s manual for additional information regarding air filter service.

CAUTION

Air intake tube must be fully seated on air box and throttle body. Inspect full perimeter if serviced. Clamps at air box and throttle body must be torqued to 49 in-lbs (5.5 N-m) or severe engine damage may occur.

• The Load/Passenger/Tire Pressure warning decal is located on the front panel of the rear cargo box 1.

• WARNING

• Passengers can be thrown off. This can cause serious injury or death.

• Never carry passengers in cargo box.

IMPROPER TIRE PRESSURE OR OVERLOADING CAN CAUSE LOSS OF CONTROL RESULTING IN SERIOUS INJURY OR DEATH.

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

• Overloading or carrying tall, off-center, or unsecured loads will increase your risk of losing control. Loads should be centered and carried as low as possible in box.

• For stability on rough or hilly terrain, reduce speed and cargo.

• Be careful if load extends over the side of the box.

• 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.

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.

• All operators should review the safety DVD provided with this vehicle and take a ROHVA® training course (www.rohva.org).

Riding in this vehicle without wearing an approved helmet and protective eyewear and footwear increases the risk of a serious injuries in the event of an accident.

Operator and/or all passengers must always wear an approved helmet that fits properly, gloves, long-sleeve shirt, long pants, over-the-ankle boots, and eye protection (goggles or face shield).

Riding in this vehicle without closed and latched cab doors increases the risk of serious injury or death in the event of an accident or rollover. Always make sure all cab doors are closed and latched while riding in this vehicle. Cab doors are NOT intended to be used as arm rests. Always keep hands and feet inside the vehicle at all times.

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.

• Do not exceed vehicle weight capacities. The vehicle’s maximum weight 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:

Gasoline is highly flammable and explosive under certain conditions.

• Always exercise extreme caution whenever handling gasoline.

• Always turn off the engine when refueling.

• Always refuel outdoors or in a well ventilated area free of any source of flame or sparks.

• NEVER carry fuel or other flammable liquids on this vehicle. Failure to follow this instruction could lead to serious burn injuries or death.

• Do not smoke or allow open flames or sparks in or near the area where refueling is performed or where gasoline is stored.

• Do not overfill the tank. Do not fill the tank neck.

• If gasoline spills on your skin or clothing, immediately wash it off with soap and water and change clothing.

This vehicle's tires are designed for off-road use only, not for use on pavement. Operating this vehicle on paved surfaces (including sidewalks, paths, parking lots and driveways) may adversely affect the handling of the vehicle and may increase the risk of loss of control and accident or rollover. Avoid operating the vehicle on pavement. If it's unavoidable, travel slowly, travel short distances and avoid sudden turns or stops.

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.

Travel slowly and use extra caution when operating on unfamiliar terrain. Always be alert to changing terrain conditions.

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.

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.

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.

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.

The engine exhaust from this product contains chemicals known to cause cancer, birth defects or other reproductive harm. Operate this vehicle only outdoors or in well-ventilated areas.

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.

Depress the brake pedal 1 to slow or stop the vehicle. Apply the brakes while starting the engine.

When the brake pedal is depressed, the brake light comes on. Check the brake light before each ride.

1. Turn the ignition switch to the ON position.

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

Push the throttle pedal 2 down 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.

The speedometer displays vehicle speed in either miles per hour (MPH) or kilometers per hour (km/h).

The tachometer displays engine speed in revolutions per minute (RPM).

Press and hold the MODE button 4 to enter or exit the settings menu. Press and release the MODE button to cycle through Area 1 modes and to select an item.

Press and release either toggle button 5 to cycle through the options menu or Area 2 modes. Press and hold either toggle button to reset an item. See Gauge Settings Menu.

The rider information center contains three areas that display mode information.

The error screen displays only when the CHECK ENGINE indicator is on or when it goes on and off during one ignition cycle. Error codes are not stored. When the key is turned OFF, the code and message is lost, but will reappear if the fault reoccurs after restarting the engine.

If the CHECK ENGINE lamp or the EPS lamp illuminates, retrieve the active error codes from the display.

• 1 Failure Mode Indicator (FMI)
• 2 Suspect Parameter Number (SPN)
• 3 Code Count

1. Press and hold the MODE button to enter the settings menu.

2. Press either toggle button to cycle to the “DIAGCODE” option. Press MODE to select.

3. More than one diagnostic code may be present. Press the toggle UP button to see if more codes are present. Press MODE to select a code.

   NOTICE

   If the displayed code is an engine fault code, the CHECK ENGINE lamp will blink. If the displayed code is an EPS fault code, the EPS lamp will blink.

4. Record the three (3) numbers displayed.

5. Press MODE to exit to the settings menu.

1. Fill the fuel tank with clean, fresh fuel. Review the fuel warnings in the Refueling section.

2. Check the oil level. Add the recommended oil as needed to maintain the oil level in the normal (safe) operating range.

3. Drive slowly at first. Select an open area that allows room to familiarize yourself with vehicle operation and handling.

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

5. Perform regular checks on fluid levels, controls and areas outlined on the daily pre-ride inspection checklist.

   During the break-in period, change both the oil and the filter at 25 hours.

6. Check fluid levels of transmission and all gearcases after the first 25 hours of operation and every 100 hours thereafter.

7. Pull only light loads.

Always break in the clutches and drive belt of new vehicles, as well as after a belt replacement.

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 and you need to replace it, always clean all debris from the PVT intake and outlet duct, the clutch, and the engine components.

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 150 lbs. (68.1 kg) tongue weight on the towing bracket.

2. When transporting heavy loads and/or when towing, always operate the vehicle in low gear and have ADC activated (if equipped).

3. Do not operate the vehicle faster than 10 MPH (16 km/h) when towing. Towing a trailer increases braking distance.

4. Do not tow more than the recommended weight for the vehicle. See the towing capacity chart below and the Specifications section for towing values.

5. Attach a trailer to the trailer hitch bracket only. Do not attach a trailer to any other location, which could result in loss of control of the vehicle.

6. Avoid towing loads on an incline. If it’s unavoidable, choose the smallest incline available, operate with extreme caution, and drive straight up or down the incline.

To extend belt life, use low gear when hauling or towing heavy cargo.

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

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

5. Stand clear and pull one of the cargo box release levers upward. Lift the front of the cargo box to dump the cargo.

6. Lower the cargo box and push down securely to latch.

   WARNING

   Operating the vehicle while the cargo box is raised could result in severe injury. The box could close unexpectedly and cause injury to the driver or passenger. 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.

• Perform the pre-ride inspection.

• 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.

• Make sure all passengers are wearing helmets, eye protection, gloves, long-sleeve shirt, long pants and over-the-ankle boots.

• Make sure all cab nets or doors (if equipped) are properly secured.

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

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

• 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.

• Vehicle handling may change with a passenger and/or cargo on board. Allow more time and distance for braking.

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

Follow these precautions when operating over obstacles:

• Always check for obstacles before operating in a new area.

• Look ahead and learn to read the terrain. Be constantly alert for hazards such as logs, rocks and low hanging branches.

• Travel slowly and use extra caution when operating on unfamiliar terrain. Not all obstacles are immediately visible.

• Move the gear selector to Low Gear, if needed.

• Avoid operating over large obstacles such as large rocks and fallen trees. If unavoidable, use extreme caution and operate slowly.

• Always have all passengers dismount and move away from the vehicle before operating over an obstacle that could cause a rollover.

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:

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

• Slow down before entering slippery areas.

• Maintain a high level of alertness, reading the trail and avoiding quick, sharp turns, which can cause skids.

• Engage all-wheel drive before wheels begin to lose traction.

  NOTICE

  Severe damage to the drive train may occur if the AWD is engaged while the wheels are spinning. Always allow the wheels to stop spinning before engaging AWD.

• Correct a skid by turning the steering wheel in the direction of the skid. Never apply the brakes during a skid.

Whenever traveling uphill, follow these precautions:

• Avoid excessively steep hills.

• ADC Models: Always operate in low gear and engage ADC 4X4 before ascending or descending a hill.

• Always travel straight uphill.

• Keep both feet on the floor.

• Always check the terrain carefully before ascending any hill. Never climb hills with excessively slippery or loose surfaces.

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

• 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.

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. Engage all-wheel drive

2. Drive slowly and use extreme caution.

3. If the vehicle begins to roll over, or if it feels as if it may roll over, immediately turn downhill.

4. Avoid obstacles and changes in terrain that may lower or raise one side of the vehicle or cause the vehicle to slide.

5. If the vehicle begins to slide downhill, immediately turn downhill to stop the slide, or stop the vehicle and maneuver slowly and carefully until the vehicle can be driven straight downhill.

When driving downhill, follow these precautions:

1. Avoid excessively steep hills.

2. Always check the terrain carefully before descending a hill. Never drive on hills with excessively slippery or loose surfaces.

3. Slow down. Never travel down a hill at high speed.

4. Always descend a hill with the transmission in forward gear. Never descend a hill with the transmission in neutral.

5. Avoid traveling down a hill at an angle, which would cause the vehicle to lean sharply to one side. Travel straight downhill.

6. Apply the brakes lightly to aid in slowing.

Your vehicle can operate through water up to a maximum recommended depth equal to the floorboards.

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 section. Give special attention to engine oil, transmission oil, front and rear gearcases (if equipped), and all grease fittings.

Follow these precautions when operating in reverse:

• Always check for obstacles or people behind the vehicle. Always inspect left and right fields of vision before backing.

• Always avoid backing downhill.

• Back slowly.

• Apply the brakes lightly for stopping.

• Avoid turning at sharp angles.

• Never open the throttle suddenly.

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 (if equipped).

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.

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 parking brake (if equipped).

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.

POLARIS recommends the use of POLARIS PS-4 5W-50 4-Cycle Oil or a similar oil. Refer to the Specifications section for capacities.

Oil may need to be changed more frequently if POLARIS PS-4 engine oil is not used. Follow the manufacturer's recommendations for ambient temperature operation. See the Polaris Products section for part numbers.

Always check the oil when the engine is cold. If the engine is hot when the oil is checked, the level will appear to be overfull.

Access the oil fill cap, dipstick and filter under the cargo box.

1. Remove all cargo from the cargo box. See Dumping the Cargo Box.

2. Position the vehicle on a level surface.

3. Place the transmission in PARK.

4. Stop the engine.

5. Stand clear and pull up on the cargo box release lever. Lift the front of the cargo box.

6. Remove the dipstick. Wipe it dry with a clean cloth.

7. Reinstall the dipstick completely. Remove the dipstick 1 and check the oil level.

8. Remove the oil fill cap 2 to add the recommended oil as needed. Maintain the oil level between the minimum and maximum marks on the dipstick. Do not overfill.

9. Reinstall the fill cap . Reinstall the dipstick.

10. Lower the cargo box and push down securely to latch.

Always change the oil and filters at the intervals outlined in the Periodic Maintenance Chart section. Always change the oil filter whenever changing oil.

The crankcase drain plug is located on the bottom of the crankcase. Access the drain plug through the access hole in the skid plate under the crankcase (see next page).

Access the oil fill cap, dipstick and filter under the cargo box.

1. Remove all cargo from the cargo box. See Dumping the Cargo Box.

2. Position the vehicle on a level surface.

3. Place the transmission in PARK.

4. Stand clear and pull up on the cargo box release lever. Lift the front of the cargo box.

5. For maximum clearance in the engine compartment, detach the cargo box shock from the base of the box.

6. Carefully detach the fuel line and spark plug wires from their retaining clips on the outlet hose, then loosen the outlet hose clamp and remove the hose from the clutch cover.

   CAUTION

   Do not allow debris or other objects to enter the clutch cover.

7. Locate the crankcase drain plug access hole in the skid plate.

8. Clean the area around the crankcase drain plug.

   CAUTION

   Hot oil can cause burns to skin. Do not allow hot oil to contact skin.

9. Place a drain pan under the engine crankcase and remove the drain plug. Allow the oil to drain completely.

10. Using an oil filter wrench, turn the filter counter-clockwise to remove it.

11. Using a clean dry cloth, clean the filter sealing surface on the crankcase.

12. Lubricate the o-ring on the new filter with a film of fresh engine oil. Check to make sure the o-ring is in good condition.

13. Install the new filter and turn by hand until the filter gasket contacts the sealing surface, then turn an additional 3/4 turn.

14. Reinstall the drain plug. Torque the drain plug to 12 ft-lbs (16 Nm).

15. Remove the oil fill cap and add 2.5 quarts (2.4 l) of recommended oil. Reinstall the fill cap.

16. Start the engine and check for leaks.

17. Stop the engine and wait 15 seconds before removing the dipstick.

18. Remove the dipstick. Wipe it dry with a clean cloth.

19. Reinstall the dipstick completely. Remove the dipstick and check the oil level.

20. Remove the oil fill cap and add oil as needed to bring the level to the upper mark on the dipstick. Do not overfill.

21. Reinstall the fill cap. Reinstall the dipstick.

22. Reinstall the outlet hose to the clutch box, routing the hose under the fuel line and spark plug wires. Make sure the clutch cover rib aligns in the notch at the end of the outlet hose. Tighten the clamp.

23. Reinstall the fuel line and spark plug wires to the retaining clips on the outlet hose.

24. Lower the cargo box and push down securely to latch.

25. Dispose of used filter and oil properly.

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.

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.

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. Place the transmission in PARK.

3. Remove the hood. See Hood.

4. View the coolant level in the overflow bottle.

5. If the coolant level is below the safe operating range, make sure the pressure cap is securely installed before adding coolant to the overflow bottle.

   NOTE

   Always add coolant through the bottle filler opening, not through the radiator pressure cap opening.

6. Reinstall the coolant bottle cap.

Check the radiator coolant level ONLY if the overflow bottle is dry. If the overflow bottle contains fluid, the radiator level should NOT be inspected.

1. Remove the hood. See 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. If the overflow bottle is dry, slowly remove the radiator pressure cap.

3. View the coolant level through the opening.

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

5. Reinstall the pressure cap securely. Use of a non-standard pressure cap will not allow the recovery system to function properly. Your POLARIS dealer, or other qualified person, can provide the correct replacement part.

6. With the pressure cap securely installed, add coolant to the overflow bottle to the recommended level. Reinstall the coolant bottle cap.

If a belt fails, always clean any debris from the duct and from the clutch and engine compartments when replacing the belt.

1. Allow hot components to cool before performing this procedure.

2. Remove the engine access cover and thoroughly clean all debris from the aluminum debris bracket and from the engine compartment.

3. Remove the clutch cover screws and open the clutch cover. (It does not have to be removed from the vehicle.) Remove all debris wrapped in and around the PVT system.

   TIP

   Use the shock/clutch tool from the tool kit to slightly open the sheaves to aid in debris removal and belt installation.

4. Remove all debris from the entire clutch air duct passage.

5. Check for signs of damage to seals on the transmission and engine. If any seals appear to be damaged, your vehicle requires prompt service. Your POLARIS dealer can assist.

   TIP

   Belt slip is responsible for creating excessive heat that destroys belts, wears clutch components and causes outer clutch covers to fail. Switch to low range while operating at slower speeds to extend the life of the PVT components (belt, cover, etc.).

There may be some instances when water is accidentally ingested into the PVT system. Use the following instructions to dry it out before operating.

1. Remove the clutch cover drain plug.

2. Allow the water to drain. Reinstall the drain plug.

3. Place the transmission in PARK. Apply the brakes.

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 10 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, or other qualified person, can assist.

Inspect the brake system routinely. Inspect the level of the brake fluid before each operation.

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.

2. Place the transmission in PARK.

3. View the brake fluid level at the reservoir in the driver’s side wheel well.

4. The level should be between the upper (MAX) and lower (MIN) level lines.

5. If the fluid level is lower than the upper level line, add brake fluid to the upper (MAX) line.

6. Apply the brake forcefully for a few seconds and check for fluid leakage around the fittings.

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 for excessive wear. Change pads when worn to 0.030" (0.762 mm).

Always replace tires when tread depth is worn to 3 mm (1/8”) or less.

Inspect the following items occasionally for tightness, and if they've been loosened for maintenance service. Do not lubricate the stud or the lug nut.

Nut Type		Location	Nut Torque
Lug Nut (Aluminum Wheels)		Front and Rear	120 ft-lbs (163 Nm)
Lug Nut (Tapered)		Front and Rear	60 ft-lbs (81 Nm)

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.

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.

If a headlight becomes damaged or inoperable, the entire headlight assembly must be replaced. Do not operate this vehicle at night or in low light conditions until the headlight is replaced. Always make sure lights are adjusted properly for best visibility.

1. Place the vehicle on a level surface with the headlight approximately 25 ft. (7.6 m) from a wall.

2. Place the transmission in PARK.

3. Measure the distance from the floor to the center of the headlight and make a mark on the wall at the same height.

4. Apply the brakes. Start the engine. Turn on the headlights.

5. Observe the headlight aim. The most intense part of the headlight beam should be aimed 8" (20 cm) below the mark placed on the wall. Include the weight of a rider on the seat while performing this step.

6. If a headlight needs adjustment, locate the adjustment screw at the back of the headlight.

7. Loosen the screw. Adjust the headlight, then tighten the screw.

8. Repeat steps 5-7 until the lamp is properly adjusted.

1. Access the battery via the front underhood storage.

2. Disconnect the black (negative) battery cable first.

3. Disconnect the red (positive) battery cable last.

4. Remove the battery hold-down strap.

5. Lift the battery out of the vehicle.

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 in the AGM Battery Maintenance and Charging section before installing the battery.

1. Ensure that the battery is fully charged.

2. Place the battery in the battery holder.

3. Coat the terminals with dielectric grease or petroleum jelly.

4. Secure the battery hold-down strap.

5. Connect and tighten the red (positive) cable first.

6. Connect and tighten the black (negative) cable last.

7. Verify that cables are properly routed.

The sealed battery is already filled with electrolyte and has been sealed and fully charged at the factory. Never pry the sealing strip off or add any other fluid to this battery.

The single most important thing about maintaining a sealed battery is to keep it fully charged. Check the battery voltage with a voltmeter or multimeter. A fully charged battery will register 12.8 V or higher. If the voltage falls below 12.5V, charge it immediately, or the battery runs the risk of sulfation and reduced battery life.

If you do not drive the vehicle for more than TWO WEEKS, Polaris recommends using a BatteryMINDer® 2012 AGM - 2 AMP charger (PN 2830438), which can be ordered through your dealer.

Polaris provides a charging accessory with your vehicle that allows easy connection to the battery through the 12V auxiliary outlet, located on the dash. During charging, place the charger outside of the vehicle and protect it from moisture.

If you plan to store the vehicle for ONE MONTH or longer, remove the battery from the vehicle, then store the battery in a cool and dry location. Continue to maintain the battery with the BatteryMINDer® 2012 AGM - 2 AMP charger.

When using an automatic charger other than a BatteryMINDer® 2012-AGM - 2 AMP charger, refer to the charger manufacturer's instructions for recharging.

If using a constant current charger (instead of BatteryMINDer® 2012 AGM - 2 AMP charger), use the guidelines below. Always verify battery condition before and 1-2 hours after the end of charging.

This POLARIS limited warranty excludes any failures that are not caused by a defect in material or workmanship. THIS WARRANTY DOES NOT COVER CLAIMS OF DEFECTIVE DESIGN. This warranty also does not cover acts of God, accidental damage, normal wear and tear, abuse or improper handling. This warranty also does not cover any vehicle, component, or part that has been altered structurally, modified, neglected, improperly maintained or used for racing, competition or purposes other than for which it was designed.

This warranty excludes damages or failures resulting from improper lubrication; improper engine timing; improper fuel; surface imperfections caused by external stress, heat, cold or contamination; operator error or abuse; improper component alignment, tension, adjustment or altitude compensation; snow, water, dirt or other foreign substance ingestion/contamination; improper maintenance; modified components; use of aftermarket or unapproved components, accessories, or attachments; use of unapproved software or calibration; unauthorized repairs; or repairs made after the warranty period expires or by an unauthorized repair center.

This warranty excludes damages or failures caused by abuse, accident, fire, or any other cause other than a defect in materials or workmanship and provides no coverage for consumable components, general wear items, or any parts exposed to friction surfaces, stresses, environmental conditions and/or contamination for which they were not designed or not intended, including but not limited to the following items:

• Wheels and tires

• Suspension components

• Brake components

• Seat components

• Clutches and components

• Steering components

• Batteries

• Light bulbs/Sealed beam lamps

• Filters

• Lubricants

• Bushings

• Finished and unfinished surfaces

• Carburetor/Throttle body components

• Engine components

• Drive belts

• Hydraulic components and fluids

• Circuit breakers/Fuses

• Electronic components

• Spark plugs

• Sealants

• Coolants

• Bearings

1. Mixing oil brands or using non-recommended oil may cause engine damage. We recommend the use of POLARIS engine oil.

2. Damage or failure resulting from the use of non-recommended lubricants or fluids is not covered by this warranty.

This warranty provides no coverage for personal loss or expense, including mileage, transportation costs, hotels, meals, shipping or handling fees, product pick-up or delivery, replacement rentals, loss of product use, loss of profits, or loss of vacation or personal time.

THE EXCLUSIVE REMEDY FOR BREACH OF THIS WARRANTY SHALL BE, AT POLARIS' OPTION, REPAIR OR REPLACEMENT OF ANY DEFECTIVE MATERIALS, COMPONENTS, OR PRODUCTS. THE REMEDIES SET FORTH IN THIS WARRANTY ARE THE ONLY REMEDIES AVAILABLE TO ANY PERSON FOR BREACH OF THIS WARRANTY. POLARIS SHALL HAVE NO LIABILITY TO ANY PERSON FOR INCIDENTAL, CONSEQUENTIAL OR SPECIAL DAMAGES OF ANY DESCRIPTION, WHETHER ARISING OUT OF EXPRESS OR IMPLIED WARRANTY OR ANY OTHER CONTRACT, NEGLIGENCE, OR OTHER TORT OR OTHERWISE. THIS EXCLUSION OF CONSEQUENTIAL, INCIDENTAL, AND SPECIAL DAMAGES IS INDEPENDENT FROM AND SHALL SURVIVE ANY FINDING THAT THE EXCLUSIVE REMEDY FAILED OF ITS ESSENTIAL PURPOSE.

THE IMPLIED WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE IS EXCLUDED FROM THIS LIMITED WARRANTY. ALL OTHER IMPLIED WARRANTIES (INCLUDING BUT NOT LIMITED TO THE IMPLIED WARRANTY OF MERCHANTABILITY) ARE LIMITED IN DURATION TO THE ABOVE SIX MONTH WARRANTY PERIOD. POLARIS DISCLAIMS ALL EXPRESS WARRANTIES NOT STATED IN THIS WARRANTY. SOME STATES DO NOT PERMIT THE EXCLUSION OR LIMITATION OF INCIDENTAL OR CONSEQUENTIAL DAMAGES OR ALLOW LIMITATIONS ON THE DURATION OF IMPLIED WARRANTIES, SO THE ABOVE LIMITATIONS MAY NOT APPLY TO YOU IF INCONSISTENT WITH CONTROLLING STATE LAW.

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.

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 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 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.