2023 Pro XD Mid-Size Gas Owner’s Manual

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.

The Belt Warning label 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.

The Proper Use Warning label is located on the OPS.

WARNING
Improper vehicle use can result in SEVERE INJURY or DEATH

WARNING
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.

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.
Part Number: 7300669 (English), 7300669–F (French Canadian)

The Proper Use Warning label is located on the OPS.

WARNING
Improper vehicle use can result in SEVERE INJURY or DEATH

WARNING
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.

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.
Part Number: 7300670 (English), 7300670–F (French Canadian)

The Passenger / Tire Pressure Warning is located on the cargo box.

WARNING

• Never carry passengers in cargo box.

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

• If total payload is greater than 500 lbs, the vehicle must be operated in LOW range.

• 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.

Read Operation & Maintenance Manual for more detailed loading information.

Part number: 7300667 (English), 7300667–F (French Canadian)

WARNING
Improper vehicle use can result in SEVERE INJURY or DEATH

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.

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.

• 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.
Part number: 7300668 (English), 7300668–F (French Canadian)

WARNING

The Maximum Payload Warning label is located on the cargo box.

CAUTION

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

Part number: 7300675 (English), 7300675–F (French Canadian)

The Clutch Cover Warning label is located on the clutch cover.

WARNING

• Moving parts hazard under belt-clutch guard. To prevent serious injury, do not operate vehicle with guard removed

• Do not modify engine or clutch. Doing so can cause part failure, possible imbalance, and excessive engine RPM which can result in serious injury or death.

The Fuel Transport Warning label 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 Air Filter Caution label is located on the air filter housing.

CAUTION
Use a Polaris approved air filter. The use of a non-Polaris approved air filter may cause engine damage. Before installing filter, ensure there is no dirt or debris in the clean side of the intake tube. 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.

Part Number 7195873 (English), 7195873–F (French Canadian)

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. Heed all safety warnings outlined in this section of the owner’s manual. See the OPERATION section of the owner’s manual for proper operating procedures.

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.

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.

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:

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.

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.

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

Before shifting into reverse gear, always check for obstacles or people behind the vehicle. When it's safe to proceed, back slowly.

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.

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.

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.

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.

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. 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. Polaris recommends selecting a hard hat or helmet that is compatible with the equipment on your vehicle and provides the greatest amount of forward clearance. Always wear a hard hat or helmet that meets or exceeds the specifications in this owner’s manual. Refer to the Personal Protective Equipment 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.

The steering wheel can be tilted upward or downward for rider preference.

Lift and hold the adjustment lever toward you while moving the steering wheel upward or downward. Release the lever when the steering wheel is at the desired position.

The vehicle is equipped with 12–volt accessory outlets on the dash. Use the outlets to power an auxiliary light or other optional accessories or lights. For service, the dash outlet connection is under the dash.

The USB outlets can be used to power accessories like a cell phone charger or a Bluetooth® speaker.

The vehicle is equipped with a dedicated port for trickle-charging the battery during periods of extended inactivity.

If you do not drive the vehicle for more than TWO WEEKS, Polaris recommends using a BatteryMINDer® charger, which can be ordered through your dealer.

Polaris provides a charging accessory with your vehicle that allows easy connection to the battery through the Battery Trickle-Charging Port, located on the dash. While charging, place the charger outside of the vehicle and protect it from moisture.

Low gear is the primary driving range for this vehicle. High gear is intended for 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 burning. See the Drive Belt Wear/Burn section for details.

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.

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:

   1 Press the MODE button.

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

   3 With 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.

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:

   1 Press the MODE button.

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

   3 With 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.

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

   NOTICE

   “OPTIONS” will display on the screen for 3 seconds before showing first menu item.

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

   Reference the image shown above:

   • 1 Press the MODE button.

   • 2 Toggle the Up/Down Buttons to change the units (12H or 24H)

   • 3 With the correct unit displayed, Press the mode button which will set the unit.

   • 4 Toggle the Up/Down Buttons to change the units (Cycles Hours)

   • 5 With the correct unit displayed, Press the mode button which will set the unit.

   • 6 Toggle the Up/Down Buttons to change the units (Cycles 10s of Minutes)

   • 7 With the correct unit displayed, Press the mode button which will set the unit.

   • 8 Toggle the Up/Down Buttons to change the units (Cycles 1s of Minutes)

   • 9 With 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.

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:

   1 Press the MODE button.

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

   3 With 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.

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:

   1 Press the MODE button.

   2 Toggle the Up/Down Buttons to change the units (Increase or Decrease Level)

   3 With 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.

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:

   1 Press the MODE button.

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

   3 With 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.

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

2. Use the up and down buttons to navigate to SPD LMT and select it by pressing the MODE button.

3. ENTER PIN will scroll across the screen. Enter the 4-digit PIN by using the up and down buttons to change the digits and the MODE button to select each digit.

4. If the wrong PIN is entered, the screen will read WRONG PIN before going back to the ENTER PIN screen. If you forget your PIN, your authorized POLARIS dealer can provide assistance.

5. If the correct PIN is entered, you will enter the Adjustable Speed Limiting menu. The screen will read MAX SPEED and will either display the currently set max speed or the word OFF if there is no max speed currently set. From here, you can use the up and down buttons to navigate to the CHANGE PIN screen and the EXIT screen. (If you want to exit the Adjustable Speed Limiting Menu, press the MODE button on the EXIT screen.)

1. To change the max speed:

   1. Press the MODE button on the MAX SPEED screen.

   2. Use the up and down buttons to toggle between the different settings: 15 mph (24 kph), 20 mph (32 kph), 25 mph (40 kph), 30 mph (48 kph), 35 mph (56 kph), or OFF. When MAX SPEED is set to OFF, the vehicle’s max speed is 40 mph (64 kph).

   3. When your preferred setting is displayed on the screen, press the MODE button to select it. This will change the max speed to your selected value and return you to the Options Menu.

   4. The max speed will remain at the selected value even if the vehicle is turned off and back on again. It does not need to be reset every time the vehicle is restarted.

1. To change the PIN:

   1. Press the MODE button on the CHANGE PIN screen.

   2. ENTER NEW PIN will scroll across the screen. Enter the new 4-digit PIN by using the up and down buttons to change the digits and the MODE button to select each digit.

   3. Once you have selected all 4 digits, NEW PIN SET will scroll across the screen. The screen will then go back to its default display.

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

To access the Diagnostic Code Screen, do the following:

1. Press and hold the MODE button to enter the Options Menu. “OPTIONS” will display on the screen for 3 seconds before showing first menu item.

1. 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.

   • 1 Display area 1 will show FMI

   • 2 Display area 2 will show SPN

   • 3 Clock Area will show Count.

   

   NOTICE

   When the gauge is displaying a fault code, the warning telltale (check engine or EPS) will blink to indicate which controller set the fault code.

2. 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.

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.

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.

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.

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.

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.

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. 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:

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.

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.

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. Slowly release the brake pedal and make sure the transmission is in PARK before exiting the vehicle.

6. 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. Turn the engine off.

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

5. Block the rear wheels on the downhill side.

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.

The oil dipstick 1 is located on the engine. Access the dipstick through the right rear wheel well.

1. Position the vehicle on a level surface.

2. Place the transmission in PARK.

3. Always clean away all dirt and debris from the dipstick area before removing the dipstick. Remove the dipstick. Wipe it dry with a clean cloth.

4. Reinstall and tighten the dipstick.

5. Remove the dipstick and check the oil level.

6. Add the recommended fluid as needed. Maintain the oil level in the safe range between the FULL 2 and ADD 3 marks. Do not overfill.

7. Reinstall and tighten the dipstick.

Always check and change the oil at the intervals outlined in the Polaris Maintenance Schedule section. Always change the oil filter whenever changing oil.

The engine drain plug 1 is located on the bottom of the crankcase. Use a 6mm hex bit socket or equivalent.

1. Position the vehicle on a level surface. Place the transmission in PARK. Apply the brakes.

2. Start the engine. Allow it to idle for two to three minutes. Stop the engine.

3. Clean the area around the drain plug.

   CAUTION

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

4. Place a drain pan beneath engine crankcase and remove the drain plug 1.

   

   

5. Allow the oil to drain completely.

6. Install a new sealing washer 2 on the drain plug.

   TIP

   The sealing surfaces on drain plug and crankcase should be clean and free of burrs, nicks or scratches.

7. Reinstall the drain plug.

   TORQUE

   12 ft-lbs (16 Nm )

8. Using a cap-style oil filter wrench or equivalent, turn the filter 3 counter-clockwise to remove it.

   

9. Using a clean dry cloth, clean the filter sealing surface on the crankcase. Make sure the old filter o-ring is completely removed.

10. 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.

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

12. Always clean away all dirt and debris from the dipstick area before removing the dipstick. Remove the oil cap 4 or the dipstick 5 and fill the sump with 1.9 liters (2 qts.) of recommended oil.

    

13. Reinstall and tighten the dipstick.

14. Make sure the transmission is in PARK. Apply the brakes.

15. Start the engine. Allow it to idle for one to two minutes.

16. Stop the engine. Inspect for leaks.

17. Re-check the oil level on the dipstick and add oil as necessary to bring the level to the upper mark on the dipstick.

18. Dispose of used filter and oil properly.

Refer to the Specifications section for the recommended spark plug type for your vehicle. Always torque spark plugs to specification.

Spark plug condition is indicative of engine operation. The spark plug firing end condition should be read after the engine is warmed up and the vehicle is driven at higher speeds. Immediately check the spark plug for correct color.

To inspect the spark plug 1, do the following:

1. Lift the cargo box to access the spark plug.

2. Remove the spark plug cap. Using a ratchet and socket set, remove the plug by rotating it counter-clockwise.

3. Reverse the procedure for spark plug installation.

4. Torque to specification.

The normal insulator tip is gray, tan or light brown. There will be few combustion deposits. The electrodes are not burned or eroded. This indicates the proper type and heat range for the engine and the service.

The tip should not be white. A white insulator tip indicates overheating, caused by use of an improper spark plug or incorrect throttle body adjustments.

The wet fouled insulator tip is black. A damp oil film covers the firing end. There may be a carbon layer over the entire nose. Generally, the electrodes are not worn. General causes of fouling are excessive oil consumption, use of non-recommended oil, or poor fuel quality.

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 POLARIS Maintenance Schedule. 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 clean the screen and radiator fins at the intervals outlined in the POLARIS Maintenance Schedule. 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. Remove 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 1.

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 2 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.

Always check and change the coolant at the intervals outlined in the POLARIS Maintenance Schedule. 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 bottle 2.

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.

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 1 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.

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

Lug Nut (Steel Wheels)		Front and Rear	49 Nm (36 ft. lbs.)
Hub Retaining Nut		Front	122 Nm (90 ft. lbs.)
		Front-CREW	122 Nm (90 ft. lbs.)
		Rear	150 Nm (111 ft. lbs.)
		Rear-CREW	245 Nm (181 ft. lbs.)

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. 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 finger-tighten.

4. Carefully lower the vehicle to the ground.

5. Torque the wheel nuts to specification.

To replace the headlight lamp, do the following:

Access the headlamp wiring harnesses through the front hood. Unplug the headlamp from the wiring harness. Be sure to pull on the connector 1, not on the wiring. Turn the lamp counter-clockwise to remove it. Install the new lamp. TIP Make sure the tab on the lamp locates properly in the housing. Reinstall the harness assembly into the headlight assembly.

To adjust the headlight beam, do the following:

1. Place the vehicle on a level surface with the headlight approximately 7.6 m (25 ft) 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 20 cm (8") 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 1 at the rear of the headlight.

   

6. Tighten the screw to adjust the lamp up. Loosen the screw to adjust the lamp down.

7. Repeat steps 4-6 until the lamp is properly adjusted.

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

To check the brake lights, do the following:

1. Turn the key to the ON position.

2. Depress the brake pedal. The brake light should come on after about 0.4 in (10 mm) of pedal travel. If the light doesn't come on, check the bulb.

1. Remove the seat to access the battery compartment.

2. On conventional batteries, remove the battery vent tube.

3. Disconnect the black (-) battery cable first. Disconnect the red (+) battery cable last.

4. Remove the battery hold-down strap.

5. Lift the battery out of the vehicle. Be careful not to tip a conventional battery sideways, which could spill electrolyte.

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.

If your factory-installed 26 AH battery cannot maintain a charge because of operation in extreme cold or with multiple electrical accessories, please see your POLARIS dealer to purchase a 53 AH battery. Before installing the 53AH or 26 AH battery into the machine, ensure the caps (if equipped) are removed from the battery terminals. Premium battery cables and a battery hold strap may be required.

1. Ensure that the battery is fully charged.

2. Place the fully charged battery in the battery holder.

3. Install the battery vent tube. The vent tube must be free of obstructions and securely installed. Route the tube away from the frame and vehicle body to prevent contact with electrolyte.

   WARNING

   Battery gases could accumulate in an improperly installed vent tube and cause an explosion, resulting in serious injury or death. Always ensure that the vent tube is free of obstructions and is securely installed as recommended.

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

5. Connect and tighten the red (+) cable first. Connect and tighten the black (-) cable last.

6. Verify that cables are properly routed. Cables should be safely tucked away at the front and rear of the battery.

7. Install the battery hold-down strap.

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.

The single most important thing about maintaining a flooded 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 THREE MONTHS 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 ONE YEAR 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.