Owners Manual
Page 38
Automatic Transmission Gear Selector FEATURES AND CONTROLS Gear The transmission gear selector is Selector located on the right side of time. 35 H: High Gear L: Low Gear N: Neutral R: Reverse P: Park To shift gears, brake to the desired gear. Whenever the ATV is left unattended, always place the transmission in heavy pulling situations and when operating at less than seven miles per hour for extended periods of the vehicle. When the engine is moving...
Automatic Transmission Gear Selector FEATURES AND CONTROLS Gear The transmission gear selector is Selector located on the right side of time. 35 H: High Gear L: Low Gear N: Neutral R: Reverse P: Park To shift gears, brake to the desired gear. Whenever the ATV is left unattended, always place the transmission in heavy pulling situations and when operating at less than seven miles per hour for extended periods of the vehicle. When the engine is moving...
Owners Manual
Page 40
... Wheel Drive System FEATURES AND CONTROLS The All Wheel Drive system is on ADC 4X4, the ADC system allows engine braking to all times. 37 When in 4X4. There is no limit to ADC 4X4 before ascending or descending a hill. ADC 4X4 Mode When the switch is controlled by the 4X4 switch. When the rear wheels regain traction, the demand drive unit will automatically engage any time...
... Wheel Drive System FEATURES AND CONTROLS The All Wheel Drive system is on ADC 4X4, the ADC system allows engine braking to all times. 37 When in 4X4. There is no limit to ADC 4X4 before ascending or descending a hill. ADC 4X4 Mode When the switch is controlled by the 4X4 switch. When the rear wheels regain traction, the demand drive unit will automatically engage any time...
Owners Manual
Page 42
... switch to neutral or park 39 Active Descent Control (ADC) System FEATURES AND CONTROLS The ADC system allows engine braking to all four of the following conditions occur: • The 4X4 switch must be in the ADC 4X4 position • Vehicle speed must be 15 mph (24 km/h) or less • The throttle must be closed (throttle lever released) • The transmission must be in gear...
... switch to neutral or park 39 Active Descent Control (ADC) System FEATURES AND CONTROLS The ADC system allows engine braking to all four of the following conditions occur: • The 4X4 switch must be in the ADC 4X4 position • Vehicle speed must be 15 mph (24 km/h) or less • The throttle must be closed (throttle lever released) • The transmission must be in gear...
Owners Manual
Page 46
... warning usually indicates that the ATV is operating at idle and high electrical load (lights, cooling fan, accessories) is applied. Fuel Gauge - The word HOT displays if the engine overheats. Do not operate the ATV if this occurs, take the ATV to your Polaris dealer for 2.5 seconds at a higher RPM or recharge the battery to protect the electronic speedometer. Instrument Cluster FEATURES AND CONTROLS Rider Information Center...
... warning usually indicates that the ATV is operating at idle and high electrical load (lights, cooling fan, accessories) is applied. Fuel Gauge - The word HOT displays if the engine overheats. Do not operate the ATV if this occurs, take the ATV to your Polaris dealer for 2.5 seconds at a higher RPM or recharge the battery to protect the electronic speedometer. Instrument Cluster FEATURES AND CONTROLS Rider Information Center...
Owners Manual
Page 51
... during the sequence. Short-to-Battery: The wire leading from the EFI module. 1. Place the transmission in less than five seconds. Stop the engine. Turn the key switch off and on the screen through this entire process. FEATURES AND CONTROLS Instrument Cluster Rider Information Center Downloading Codes The EFI diagnostic mode is for all major repairs. See page 49 for blink codes. Turn the key switch to begin the diagnostic sequence...
... during the sequence. Short-to-Battery: The wire leading from the EFI module. 1. Place the transmission in less than five seconds. Stop the engine. Turn the key switch off and on the screen through this entire process. FEATURES AND CONTROLS Instrument Cluster Rider Information Center Downloading Codes The EFI diagnostic mode is for all major repairs. See page 49 for blink codes. Turn the key switch to begin the diagnostic sequence...
Owners Manual
Page 52
... Throttle Position Sensor High Throttle Position Sensor Out of Adjustment Gear Sensor Signal System Voltage Low System Voltage High Ignition Coil A Prim/Sec Circuit Malfunction: Open Load/Short-to-Ground Ignition Coil A Prim/Sec Circuit Malfunction: Shorted Load/Short-to-Battery Ignition Coil B Prim/Sec Circuit Malfunction: Open Load/Short-to-Ground Ignition Coil B Prim/Sec Circuit Malfunction: Shorted Load/Short-to-Battery Air Temp Sensor Low Voltage Air Temp Sensor High Voltage Engine Coolant...
... Throttle Position Sensor High Throttle Position Sensor Out of Adjustment Gear Sensor Signal System Voltage Low System Voltage High Ignition Coil A Prim/Sec Circuit Malfunction: Open Load/Short-to-Ground Ignition Coil A Prim/Sec Circuit Malfunction: Shorted Load/Short-to-Battery Ignition Coil B Prim/Sec Circuit Malfunction: Open Load/Short-to-Ground Ignition Coil B Prim/Sec Circuit Malfunction: Shorted Load/Short-to-Battery Air Temp Sensor Low Voltage Air Temp Sensor High Voltage Engine Coolant...
Owners Manual
Page 54
... clutches and belt by operating at sustained idle. 5. Perform regular checks on fluid levels, controls and areas outlined on the dipstick. Add oil if necessary to familiarize yourself with gasoline. Do not operate at slower speeds during the break-in period as recommended. Fill the fuel tank with vehicle operation and handling. 4. See page 80. Vary the throttle positions. Break-In Period OPERATION Engine...
... clutches and belt by operating at sustained idle. 5. Perform regular checks on fluid levels, controls and areas outlined on the dipstick. Add oil if necessary to familiarize yourself with gasoline. Do not operate at slower speeds during the break-in period as recommended. Fill the fuel tank with vehicle operation and handling. 4. See page 80. Vary the throttle positions. Break-In Period OPERATION Engine...
Owners Manual
Page 73
... the vehicle, include the weight of control or brake instability. NEVER EXCEED THE MAXIMUM WEIGHT CAPACITY of gravity and creates a less stable operating condition. WEIGHT DISTRIBUTION in rough terrain, while cornering, or while ascending or descending a hill. Always attach the tow load to maintain stable driving conditions when operating over rough or hilly terrain. Reduce load weight when cargo is lowered and latched before...
... the vehicle, include the weight of control or brake instability. NEVER EXCEED THE MAXIMUM WEIGHT CAPACITY of gravity and creates a less stable operating condition. WEIGHT DISTRIBUTION in rough terrain, while cornering, or while ascending or descending a hill. Always attach the tow load to maintain stable driving conditions when operating over rough or hilly terrain. Reduce load weight when cargo is lowered and latched before...
Owners Manual
Page 74
... terrain, reduce speed and cargo weight to extend belt life. 4. Always load the cargo box with the load as far forward as possible. Balance, handling, and control may be mounted as low as possible. 2. Do not obstruct the headlight beam with extreme caution whenever hauling or towing loads. Unintentional dumping will result if weight is placed in the specifications section of...
... terrain, reduce speed and cargo weight to extend belt life. 4. Always load the cargo box with the load as far forward as possible. Balance, handling, and control may be mounted as low as possible. 2. Do not obstruct the headlight beam with extreme caution whenever hauling or towing loads. Unintentional dumping will result if weight is placed in the specifications section of...
Owners Manual
Page 75
... the vehicle and will void your Polaris ATV. NOTICE: Using an improper hitch or exceeding the maximum tongue weight capacity can result in serious damage to the hitch point. Maximum 4" (10 cm) Maximum Towing Capacities Do not exceed the following maximum capacities when towing. Avoid towing on your ATV warranty. Remove the hitch from the ATV when not towing a trailer. If towing a load, reduce rear rack cargo weight by...
... the vehicle and will void your Polaris ATV. NOTICE: Using an improper hitch or exceeding the maximum tongue weight capacity can result in serious damage to the hitch point. Maximum 4" (10 cm) Maximum Towing Capacities Do not exceed the following maximum capacities when towing. Avoid towing on your ATV warranty. Remove the hitch from the ATV when not towing a trailer. If towing a load, reduce rear rack cargo weight by...
Owners Manual
Page 80
... 6M 6M 6M 6M Battery X Rear gearcase oil (if equipped) X Transmission oil X Demand drive fluid X Engine breather E filter (if equipped) X General lubrication Shift linkage Q Steering X Front suspension X Rear suspension E ETC Switch Q Throttle Cable/ E Throttle Body Intake Duct Drive belt Cooling system (if applicable) X Engine oil change X Oil filter change yearly Inspect; change 77 adjust; Inspect, lubricate Lubricate Lubricate Lubricate Inspect; replace if necessary Inspect duct for proper sealing/air leaks Inspect; change 1000 (1600) Inspect coolant strength seasonally...
... 6M 6M 6M 6M Battery X Rear gearcase oil (if equipped) X Transmission oil X Demand drive fluid X Engine breather E filter (if equipped) X General lubrication Shift linkage Q Steering X Front suspension X Rear suspension E ETC Switch Q Throttle Cable/ E Throttle Body Intake Duct Drive belt Cooling system (if applicable) X Engine oil change X Oil filter change yearly Inspect; change 77 adjust; Inspect, lubricate Lubricate Lubricate Lubricate Inspect; replace if necessary Inspect duct for proper sealing/air leaks Inspect; change 1000 (1600) Inspect coolant strength seasonally...
Owners Manual
Page 81
... for leaks 1000 (1600) Inspect 1000 (1600) Inspect 1000 (1600) Inspect; replace as needed 100 H 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 12 M Fuel system X Radiator (if applicable) X Cooling hoses (if applicable) X Engine mounts Exhaust muffler/ pipe E Q Spark plug X Wiring Q Clutches (drive and driven) bearings 100 H 100 H 200 H 200 H 200 H 12 M 12 M 24 M 24 M 24 M Q Front wheel Q Brake fluid Q ADC fluid (ADC models) X Fuel filter E Q Spark arrestor...
... for leaks 1000 (1600) Inspect 1000 (1600) Inspect 1000 (1600) Inspect; replace as needed 100 H 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 12 M Fuel system X Radiator (if applicable) X Cooling hoses (if applicable) X Engine mounts Exhaust muffler/ pipe E Q Spark plug X Wiring Q Clutches (drive and driven) bearings 100 H 100 H 200 H 200 H 200 H 12 M 12 M 24 M 24 M 24 M Q Front wheel Q Brake fluid Q ADC fluid (ADC models) X Fuel filter E Q Spark arrestor...
Owners Manual
Page 101
...) Cast Aluminum Steel 27 ft. Place the transmission in an accident or overturn. Lower the vehicle to specification. MAINTENANCE Tires Wheel Installation 1. Place the wheel on the hub with the valve stem toward the outside and rotation arrows on the tire pointing toward forward rotation. 4. Loose nuts could cause a tire to specification. 90 ft. WARNING! Always ensure that all nuts are torqued to...
...) Cast Aluminum Steel 27 ft. Place the transmission in an accident or overturn. Lower the vehicle to specification. MAINTENANCE Tires Wheel Installation 1. Place the wheel on the hub with the valve stem toward the outside and rotation arrows on the tire pointing toward forward rotation. 4. Loose nuts could cause a tire to specification. 90 ft. WARNING! Always ensure that all nuts are torqued to...
Owners Manual
Page 105
... sure lights are adjusted properly for best visibility. Lift the pod cover and disconnect the speedometer harnesses from the wiring harness. Unplug the headlamp from the speedometer. Apply dielectric grease to cool before servicing. 5. Clean headlights frequently and replace burned ...headlight pod. 2. Be sure to pull on the connector, not on the lower front corners of the lamp. MAINTENANCE Lights Poor lighting can cause burns to skin. CAUTION!Hot components can result in the housing. 8. Turn the lamp counterclockwise to remove it with bare fingers. Oil from the rear...
... sure lights are adjusted properly for best visibility. Lift the pod cover and disconnect the speedometer harnesses from the wiring harness. Unplug the headlamp from the speedometer. Apply dielectric grease to cool before servicing. 5. Clean headlights frequently and replace burned ...headlight pod. 2. Be sure to pull on the connector, not on the lower front corners of the lamp. MAINTENANCE Lights Poor lighting can cause burns to skin. CAUTION!Hot components can result in the housing. 8. Turn the lamp counterclockwise to remove it with bare fingers. Oil from the rear...
Owners Manual
Page 107
... to remove it from the locking tabs. 8. MAINTENANCE Lights Headlight Housing Replacement 1. Lift the pod slightly while depressing the tabs at the rear of the headlight pod. 2. Adjust the headlight aim by 5 1/8" turning the adjusting knob. (13 cm) 104 Pull the headlight housing up to release it from the locking tabs. 7. Lift the pod cover and disconnect the speedometer harnesses from the wiring harness. 5. Lift the adjusting knob up...
... to remove it from the locking tabs. 8. MAINTENANCE Lights Headlight Housing Replacement 1. Lift the pod slightly while depressing the tabs at the rear of the headlight pod. 2. Adjust the headlight aim by 5 1/8" turning the adjusting knob. (13 cm) 104 Pull the headlight housing up to release it from the locking tabs. 7. Lift the pod cover and disconnect the speedometer harnesses from the wiring harness. 5. Lift the adjusting knob up...
Owners Manual
Page 126
...; ADC fluid (ADC models) (change every two years) • Rear gearcase (if equipped) • Transmission • Brake fluid (change every two years and any time the fluid looks dark or contaminated) • Coolant (test strength/fill) Fog the Engine 1. Remove the spark plug and add 2-3 tablespoons of gasoline. 123 Cleaning and Storage Storage Tips MAINTENANCE Fluid Levels Inspect the fluid levels. Start the engine. Apply dielectric grease to specification. 4. If Polaris fuel system...
...; ADC fluid (ADC models) (change every two years) • Rear gearcase (if equipped) • Transmission • Brake fluid (change every two years and any time the fluid looks dark or contaminated) • Coolant (test strength/fill) Fog the Engine 1. Remove the spark plug and add 2-3 tablespoons of gasoline. 123 Cleaning and Storage Storage Tips MAINTENANCE Fluid Levels Inspect the fluid levels. Start the engine. Apply dielectric grease to specification. 4. If Polaris fuel system...
Owners Manual
Page 137
SPECIFICATIONS Sportsman X2 500 EFI Maximum Weight Capacity Dry Weight Front Rack/Storage Box Capacity Rear Storage Box Capacity Receiver Hitch Tongue Capacity Hitch Towing Rating Unbraked Trailer Towing Capacity Overall Length Overall Width Overall Height Wheelbase Ground Clearance Minimum Turning Radius Fuel Capacity Engine Oil Capacity Coolant Capacity Demand Drive Fluid Capacity Transmission Oil Capacity Engine Displacement Bore x Stroke Alternator Output Compression Ratio Fuel System Ignition System Ignition Timing Spark Plug Spark Plug Gap Lubrication System Driving System Type Front ...
SPECIFICATIONS Sportsman X2 500 EFI Maximum Weight Capacity Dry Weight Front Rack/Storage Box Capacity Rear Storage Box Capacity Receiver Hitch Tongue Capacity Hitch Towing Rating Unbraked Trailer Towing Capacity Overall Length Overall Width Overall Height Wheelbase Ground Clearance Minimum Turning Radius Fuel Capacity Engine Oil Capacity Coolant Capacity Demand Drive Fluid Capacity Transmission Oil Capacity Engine Displacement Bore x Stroke Alternator Output Compression Ratio Fuel System Ignition System Ignition Timing Spark Plug Spark Plug Gap Lubrication System Driving System Type Front ...
Owners Manual
Page 138
SPECIFICATIONS Sportsman X2 500 EFI Transmission Gear Reduction, Low Gear Reduction, Reverse Gear Reduction, High Drive Ratio, Front Tires/Pressure, Front Tires/Pressure, Rear Brakes, Front Brakes, Rear Brake, Auxiliary Brake, Parking Headlight Taillights Brake Light Instrument Cluster Automatic EBS (Engine Braking System) with E-Z Shift H/L/N/R/P 23.91:1 21.74:1 10.57:1 3.82:1 25x8-12 / 5 psi 25x11-12 / 5 psi Single-Control Hydraulic Disc Single-Control Hydraulic Disc Foot-Activated Hydraulic Disc Hydraulic lock, all wheel 1 Single Beam on Headlight Pod (50 watt) 2 Single Beam on Bumper (37...
SPECIFICATIONS Sportsman X2 500 EFI Transmission Gear Reduction, Low Gear Reduction, Reverse Gear Reduction, High Drive Ratio, Front Tires/Pressure, Front Tires/Pressure, Rear Brakes, Front Brakes, Rear Brake, Auxiliary Brake, Parking Headlight Taillights Brake Light Instrument Cluster Automatic EBS (Engine Braking System) with E-Z Shift H/L/N/R/P 23.91:1 21.74:1 10.57:1 3.82:1 25x8-12 / 5 psi 25x11-12 / 5 psi Single-Control Hydraulic Disc Single-Control Hydraulic Disc Foot-Activated Hydraulic Disc Hydraulic lock, all wheel 1 Single Beam on Headlight Pod (50 watt) 2 Single Beam on Bumper (37...
Owners Manual
Page 139
SPECIFICATIONS Sportsman X2 800 EFI Maximum Weight Capacity Dry Weight Front Rack/Storage Box Capacity Rear Storage Box Capacity Receiver Hitch Tongue Capacity Hitch Towing Rating Unbraked Trailer Towing Capacity* Overall Length Overall Width Overall Height Wheelbase Ground Clearance Minimum Turning Radius Fuel Capacity Engine Oil Capacity Coolant Capacity Demand Drive Fluid Capacity Transmission Oil Capacity Engine Displacement Bore x Stroke Alternator Output Compression Ratio Fuel System Ignition System Ignition Timing Spark Plug Spark Plug Gap Lubrication System Driving System Type Front ...
SPECIFICATIONS Sportsman X2 800 EFI Maximum Weight Capacity Dry Weight Front Rack/Storage Box Capacity Rear Storage Box Capacity Receiver Hitch Tongue Capacity Hitch Towing Rating Unbraked Trailer Towing Capacity* Overall Length Overall Width Overall Height Wheelbase Ground Clearance Minimum Turning Radius Fuel Capacity Engine Oil Capacity Coolant Capacity Demand Drive Fluid Capacity Transmission Oil Capacity Engine Displacement Bore x Stroke Alternator Output Compression Ratio Fuel System Ignition System Ignition Timing Spark Plug Spark Plug Gap Lubrication System Driving System Type Front ...
Owners Manual
Page 140
SPECIFICATIONS Sportsman X2 800 EFI Transmission Gear Reduction, Low Gear Reduction, Reverse Gear Reduction, High Drive Ratio, Front Tires/Pressure, Front Tires/Pressure, Rear Brakes, Front Brakes, Rear Brake, Auxiliary Brake, Parking Headlight Taillights Brake Light Instrument Cluster Automatic EBS (Engine Braking System) with E-Z Shift H/L/N/R/P 23.91:1 21.74:1 8.28:1 3.82:1 25x8-12 / 5 psi 25x11-12 / 5 psi Single-Control Hydraulic Disc Single-Control Hydraulic Disc Foot-Activated Hydraulic Disc Hydraulic lock, all wheel 1 Single Beam on Headlight Pod (50 watt) 2 Single Beam on Bumper (37.5 ...
SPECIFICATIONS Sportsman X2 800 EFI Transmission Gear Reduction, Low Gear Reduction, Reverse Gear Reduction, High Drive Ratio, Front Tires/Pressure, Front Tires/Pressure, Rear Brakes, Front Brakes, Rear Brake, Auxiliary Brake, Parking Headlight Taillights Brake Light Instrument Cluster Automatic EBS (Engine Braking System) with E-Z Shift H/L/N/R/P 23.91:1 21.74:1 8.28:1 3.82:1 25x8-12 / 5 psi 25x11-12 / 5 psi Single-Control Hydraulic Disc Single-Control Hydraulic Disc Foot-Activated Hydraulic Disc Hydraulic lock, all wheel 1 Single Beam on Headlight Pod (50 watt) 2 Single Beam on Bumper (37.5 ...