Document Outline

• WELCOME
• TABLE OF CONTENTS
  • Introduction 4
  • Safety 7
  • Features and Controls 24
  • Operation 39
  • Cleaning 53
  • Storage 55
  • Maintenance 57
  • Specifications 74
  • Polaris Products 75
  • Troubleshooting 76
  • Warranty 76
  • Maintenance Log 82
  • Index 84
• INTRODUCTION
  • WARNING
  • CAUTION
  • NOTICE
• INTRODUCTION
  • WARNING
• INTRODUCTION
  • Vehicle Identification Numbers
    • Motor Serial Number
      • Vehicle Model Number:
      • Frame VIN:
      • Vehicle Serial Number:
      • Key Number:
• SAFETY
  • Equipment Modifications
• SAFETY
  • Operator Safety
  • WARNING
    • Operating Without Instruction
    • Age Restrictions
• SAFETY
  • Operator Safety
    • Ventilation When Charging Batteries
    • Failure to Inspect Before Operating
    • Using Alcohol or Drugs
• SAFETY
  • Operator Safety
    • Seat Belts
    • Poor Visibility
  • Operating the vehicle in darkness or inclement weather could result in a collision or accident, especially if operating on a roa...
    • Accessories
  • Non-approved accessories may seriously affect vehicle stability. Using accessories not approved by Polaris for use on this vehicle could cause loss of control or an accident. Never operate with accessories not approved by Polaris for use on this vehicle.
• SAFETY
  • Operator Safety
    • Carrying a Passenger
    • Carrying Multiple Passengers
    • Operating on Public Roads
    • Operating at Excessive Speeds
• SAFETY
  • Operator Safety
    • Turning Improperly
    • Physical Control of the Vehicle
    • Jumps and Stunts
    • Descending Hills Improperly
• SAFETY
  • Operator Safety
    • Improper Hill Climbing
    • Crossing Slopes
    • Stalling While Climbing a Hill
    • Operating in Unfamiliar Terrain
• SAFETY
  • Operator Safety
    • Operating on Slippery Terrain
    • Operating Improperly in Reverse
    • Improper Tire Maintenance
• SAFETY
  • Operator Safety
    • Operating Over Obstacles
    • Skidding or Sliding
    • Do not operate on excessively slippery surfaces.
    • Operating a Damaged Vehicle
    • Unauthorized Use of the Vehicle
• SAFETY
  • Operator Safety
    • Precautions During Maintenance
    • FOR MORE INFORMATION ABOUT SAFETY
    • call Polaris at 1-800-342-3764.
• SAFETY
  • Safety Labels and Locations
    • Discretionary Warning
• SAFETY
  • Safety Labels and Locations
• SAFETY
  • Safety Labels and Locations
    • Age Warning
    • Age Warning
• SAFETY
  • Safety Labels and Locations
    • Discretionary Warning
    • Discretionary Warning
• SAFETY
  • Safety Labels and Locations
    • CAUTION, MASTER SWITCH
    • Caution, Master Switch
• SAFETY
  • Safety Labels and Locations
    • Passenger Safety Warning
    • ??????????
• SAFETY
  • Safety Labels and Locations
    • Warning Battery
    • 7176201
• FEATURES AND CONTROLS
  • Component Locations
    • Steering Wheel
• FEATURES AND CONTROLS
• Component Locations
  • Tail Light/Brake Light/Running Light
• FEATURES AND CONTROLS
  • Component Locations
    • SIDE VIEW
• FEATURES AND CONTROLS
  • Forward/ Reverse Switch
    • 12V Accessory Power Outlet
    • Key Switch
• FEATURES AND CONTROLS
  • Forward/Reverse Switch
  • Forward
    • Headlight Switch
  • High Beam
• FEATURES AND CONTROLS
  • Battery Discharge Indicator (BDI)
  • Battery Discharge Indicator
• FEATURES AND CONTROLS
  • Master On/Off Switch
  • OFF
    • Multifunction Light
  • Multifunction Light
• FEATURES AND CONTROLS
  • Multifunction Light
    • Flash Sequence
    • Solution
    • OFF
    • If the light does not illuminate, verify that the master on/off switch is in the ON position. Check battery cable connections.
    • 1 Flash
    • The system controller has an internal error. See your Polaris dealer for service.
    • 2 Flashes
    • Move the master on/off switch to OFF. Inspect electrical connections to the direction selector switch. Return the master on/ off switch to ON. If the light continues to flash, see your Polaris dealer for service.
    • 3 Flashes
    • Move the master on/off switch to OFF. Inspect electrical connections to the motor. Return the master on/off switch to ON. If the light continues to flash, see your Polaris dealer for service.
    • 4 Flashes
    • The line contactor requires service. See your Polaris dealer for service.
    • 6 Flashes
    • Move the master on/off switch to OFF. Inspect electrical connections to the accelerator pedal. Return the master on/off switch to ON. If the light continues to flash, see your Polaris dealer for service.
    • 7 Flashes
    • Battery voltage is low. Move the master on/off switch to OFF. Check battery cable connections. Return the master on/off switch to ON. If the light continues to flash, move the master on/off switch to OFF and use a battery tester to check each battery.
• FEATURES AND CONTROLS
  • Batteries
• FEATURES AND CONTROLS
  • Brakes
    • Accelerator Pedal
  • Park Brake
  • Brake Pedal
• FEATURES AND CONTROLS
  • Accelerator Pedal
    • Turn Signals/Hazard Light
    • Hazard Light Plate
• FEATURES AND CONTROLS
  • Seats
    • Driver’s Seatback Adjustment
    • Front Seat Adjustment
• FEATURES AND CONTROLS
  • Seats
    • Open Seat to Access Batteries
      • 1. Make sure the driver’s side seatback is in rearmost position
      • 2. Rotate the driver and passenger buckles underneath the seatbacks
      • 3. Grasping the driver or passenger side armrest, rotate the seat forward until it rests against the steering wheel.
    • To Completely Remove the Seat
    • Seat Cleaning
• FEATURES AND CONTROLS
  • Seat Belts
    • 1. Place the belt across your lap as low on your hips as possible. Make sure that the belt is not twisted.
    • 2. Push the latch plate into the buckle until it clicks.
    • 3. Release the strap, it will self-tighten.
    • To release the seat belt, press the square red button in the buckle's center.
    • Seat Belt Inspection
      • 1. Push the latch plate into the buckle until it clicks. The latch plate must slide smoothly into the buckle. A click indicates that it's securely latched.
      • 2. Push the red release latch in the middle of the buckle to make sure it releases freely.
      • 3. Check the belt webbing for wear, cuts or damage. If any irregularities are found, have the seat belt system checked and/or replaced by an authorized Polaris dealer.
      • 4. To clean dirt or debris from the seat belts, sponge the straps with mild soap and water. Do not use bleach, dye or household detergents.
• FEATURES AND CONTROLS
  • Passenger Seat/Bag Retainer
    • Passenger Release Handle
• OPERATION
  • Brake System Break-in
  • Pre-Ride Inspection
  • Batteries
  • Ensure batteries are fully charged
  • 43
  • Brake system
  • Ensure proper operation
  • 33
  • 63
  • Steering
  • Ensure free operation
  • 63
  • Tires
  • Inspect condition and pressure
  • 65
  • Wheels/fasteners
  • Inspect, ensure fastener tightness
  • 66
  • Frame nuts, bolts, fasteners
  • Inspect, ensure tightness
  • -
  • Accelerator
  • Ensure proper operation
  • 34
  • Indicator lights/switches
  • Ensure proper operation
  • 27-31
  • Headlamp
  • Check operation, apply Polaris dielectric grease when lamp is replaced
  • 69
  • Seat Latches
  • Push down on both seat backs to ensure the latches are secure
  • 38
  • Seat Belts
  • Check length of belt for damage, check latches for proper operation
  • 37
• OPERATION
  • New Operator Driving Procedures
    • 1. Read and understand the owner's manual and all warning and instruction labels before operating this vehicle.
    • 2. Disconnect the battery charger (if connected). See page 72.
    • 3. Perform the pre-ride inspection. See page 39.
    • 4. Do not carry a passenger until you have at least two hours of driving experience with this vehicle.
    • 5. Sit in the driver's seat and fasten the seat belt.
    • 6. Make sure the direction selector switch is in the proper position for your intended direction of travel.
    • 7. Make sure the front wheels are turned in the intended direction of travel.
    • 8. Apply the brakes.
    • 9. Turn the key to the ON position.
    • 10. Select an open area that allows room to familiarize yourself with vehicle operation and handling. Check for obstacles and people in your driving area.
    • 11. Keeping both hands on the steering wheel, release the brakes and depress the accelerator with your right foot to begin driving.
    • 12. Drive slowly at first. On level surfaces, practice starting, stopping, turning, maneuvering, using the accelerator and brakes and driving in reverse. Learn how the vehicle handles when making both left and right turns at a slow speed.
    • 13. Increase speed only after mastering all maneuvers at a slow speed.
    • 14. After you become skilled at making turns and begin to operate at faster speeds, follow these precautions:
• OPERATION
  • New Operator Driving Procedures
    • Stopping
      • 1. Release the accelerator pedal completely.
      • 2. Depress the brake pedal and brake to a complete stop.
    • Parking
      • 1. Stop the vehicle on a level surface.
      • 2. Engage the park brake.
      • 3. If the vehicle will be parked for more than a few minutes, turn the key off. Remove the key and move the direction selector switch to the neutral position.
      • 4. Any time the vehicle will be parked for more than a few hours, move the Master On/Off switch to the OFF position and follow the recommended storage procedures. See page 55.
• OPERATION
  • Driving with Passengers
    • 1. Complete the New Operator Driving Procedures outlined on pages 40-41.
    • 2. Perform the pre-ride inspection. See page 39.
    • 3. Make sure all occupants are properly seated and have their seatbelts secured.
    • 4. Slow down. Always travel at a speed appropriate for your skills, your passenger's skills, and operating conditions. Avoid unexpected or aggressive maneuvers that could cause discomfort or injury to your passengers.
    • 5. Vehicle handling may change with passengers on board. Allow more time and distance for braking.
    • 6. Always follow all operating guidelines as outlined on safety labels and in this manual.
• OPERATION
  • Battery Use
• OPERATION
  • Driving on Slippery Surfaces
  • WARNING
    • 1. Slow down before entering slippery areas.
    • 2. Maintain a high level of alertness, reading the trail and avoiding quick, sharp turns, which can cause skids.
    • 3. Correct a skid by turning the steering wheel in the direction of the skid. Never apply the brakes during a skid.
• OPERATION
  • Driving Uphill
    • 15° maximum
      • 1. Always check the terrain carefully before ascending a hill.
      • 2. Avoid steep hills (15° maximum).
      • 3. Drive straight uphill.
      • 4. Never climb hills with excessively slippery or loose surfaces.
      • 5. Proceed at a steady rate of speed and accelerator position. Never apply full throttle suddenly.
      • 6. Avoid unnecessary changes in speed or direction.
      • 7. 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.
      • 8. If the vehicle stalls while climbing a hill, apply the brakes. Place the Direction Selector switch in reverse and slowly allow the vehicle to roll straight downhill while applying light brake pressure to control speed.
• OPERATION
  • Driving Downhill
    • 15° maximum
      • 1. Avoid steep hills (15° maximum).
      • 2. Always descend a hill with the direction selector switch in forward. Never descend a hill with the switch on neutral.
      • 3. Use the brake pedal to control speed when descending a hill.
      • 4. Always check the terrain carefully before descending a hill.
• OPERATION
  • Driving in Reverse
    • 1. Always check for obstacles or people behind the vehicle.
    • 2. Apply the pedal lightly. Never press quickly on the accelerator pedal.
    • 3. Back slowly.
    • 4. Apply the brakes lightly for stopping.
    • 5. Avoid making sharp turns.
• OPERATION
  • Driving on a Sidehill (Sidehilling)
    • 1. Drive slowly and use extreme caution.
    • 2. If the vehicle begins to overturn, or if it feels as if it may overturn, immediately turn downhill.
    • 3. Avoid obstacles and changes in terrain that may lower or raise one side of the vehicle or cause the vehicle to slide.
    • 4. 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.
• OPERATION
  • Parking on an Incline
    • 1. Set the Parking Brake.
    • 2. Turn the Forward/Reverse switch to Neutral.
    • 3. Block the rear wheels on the downhill side, or park the vehicle in a sidehill position instead
• OPERATION
  • Hauling Cargo
  • WARNING
• OPERATION
  • Towing the Vehicle
    • 1. Place the direction selector switch in the NEUTRAL position.
    • 2. Move the master ON/OFF switch to the OFF position.
    • 3. Turn the key off.
    • 4. Always follow these precautions when towing this vehicle:
• OPERATION
  • Transporting the Vehicle on a Trailer
    • 1. Place the direction selector switch in the NEUTRAL position.
    • 2. Engage the park brake.
    • 3. Remove the key to prevent loss during transporting.
    • 4. If the trailer is not enclosed, remove the windshield (if equipped).
    • 5. Always tie the frame of the Polaris vehicle to the trailer securely with suitable straps or rope.
    • 6. Always follow these precautions when trailering the vehicle:
    • 7. Remove all personal equipment and/or golf bags before towing vehicle on a trailer.
• CLEANING
  • Washing the Vehicle
    • 1. Use a professional-type washing cloth, cleaning the upper body first and the lower parts last.
    • 2. Rinse with clean water frequently.
    • 3. Dry surfaces with a chamois to prevent water spots.
    • Washing Tips
• CLEANING
  • Washing the Vehicle
  • Polishing the Vehicle
    • Polishing Tips
• STORAGE
  • Storing the Vehicle
    • 1. Make any necessary repairs and clean the vehicle. See page 53.
    • 2. Clean the batteries. See page 72.
    • 3. Store the vehicle out of the sun in a cool, dry place.
    • 4. Be sure the storage area is well ventilated.
    • 5. Move the Master On/Off switch to the OFF position.
    • 6. Do not engage the park brake.
    • 7. Verify that tire pressure is at specification.
    • 8. Block the wheels to prevent rolling.
    • 9. Fully charge the batteries. Leave the charger connected to maintain a full charge during the storage period, or check battery...
• STORAGE
  • Removal from Storage
    • 1. Inspect all battery connections.
    • 2. Verify that batteries are fully charged.
    • 3. Verify that tire pressure is at specification.
    • 4. Perform the pre-ride inspection. See page 39.
    • 5. Inspect and verify the tightness of the bolts, nuts and other fasteners.
    • 6. Lubricate at the intervals outlined in the Periodic Maintenance Chart beginning on page 57.
• MAINTENANCE
  • Periodic Maintenance Chart
    • Severe Use Definition
• MAINTENANCE
  • Periodic Maintenance Chart
    • Maintenance Chart Key
    • Item
    • Maintenance Interval
    • Remarks
• MAINTENANCE
  • Periodic Maintenance Chart
    • Item
    • Maintenance Interval
    • Remarks
      • u Perform these procedures more often for vehicles subjected to severe use.
      • n Have an authorized Polaris dealer perform these services.
• MAINTENANCE
  • Lubrication Recommendations
    • Item
    • Lube
    • Method
    • Lubricate
    • Kingpin
• MAINTENANCE
  • Transaxle
    • Transaxle Specification Chart
    • Transaxle
    • Lubricant
    • Capacity
    • Fill Plug Torque
• MAINTENANCE
  • Speed Control System/Accelerator Pedal
  • WARNING
• MAINTENANCE
  • Brakes
  • Steering Wheel Inspection
    • 1. Position the vehicle on level ground.
    • 2. Lightly turn the steering wheel left and right.
    • 3. If there is excessive freeplay or strange noises, or the steering feels rough or "catchy," have the steering system inspected by an authorized Polaris dealer.
• MAINTENANCE
  • Suspension Settings
    • Adjustment Cam
• MAINTENANCE
  • Tires
  • WARNING
    • Tire Tread Depth
    • 1/8" (3 mm)
      • Tire Rotation
    • FRONT
• MAINTENANCE
  • Axle and Wheel Nut Torque Specifications
  • Front
  • 40 ft. lbs.
  • (54 Nm)
  • Rear
  • 95-115 lbs.
  • (129-156 Nm)
    • Wheel Lug Nut
    • 90 ft. lbs. (122 Nm)
    • Front Hub Nut
    • 40 ft. lbs. (54 Nm)
    • Rear Hub Nut
    • 95-115 ft. lbs. (129-156 Nm)
• MAINTENANCE
  • Tires
    • Wheel Removal
      • 1. Position the vehicle on a flat level surface.
      • 2. Place the gear selector switch in neutral.
      • 3. Apply the parking brake.
      • 4. Loosen the wheel nuts slightly.
      • 5. Elevate one side of the vehicle by placing a suitable stand under the frame. Do not ever elevate both rear wheels at the same time! Parking brake only locks rear wheels, and vehicle can roll.
      • 6. Remove the wheel nuts. Remove the wheel.
• MAINTENANCE
  • Tires
    • Wheel Installation
      • 1. Place the transmission in NEUTRAL.
    • Rear
      • 2. Place the wheel in the correct position on the wheel hub. Be sure the valve stem is toward the outside and rotation arrows on the tire point 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. See page 66.
• MAINTENANCE
  • Lights
    • Headlight Lamp Replacement
      • 1. Unplug the headlamp from the wiring harness. Be sure to pull on the connector, not on the wiring.
    • Wiring
    • Harness
      • 2. Turn the lamp counterclockwise to remove it.
      • 3. Install the new lamp. Make sure the tab on the lamp locates properly in the housing.
      • 4. Reinstall the harness assembly into the headlight assembly.
• MAINTENANCE
  • Lights
    • Brake Lights
      • 1. Turn the ignition switch to the ON position.
      • 2. Apply the brakes.If the light doesn't come on, check the wiring, the brake switch or the tail light assembly.
• MAINTENANCE
  • Batteries
  • WARNING
  • WARNING
  • WARNING
  • WARNING
• MAINTENANCE
  • Batteries
    • Battery Cleaning
    • Battery Charging
      • 1. Position the vehicle indoors on a level surface. Make sure the charging area is well ventilated.
    • Charging Receptacle
      • 2. Open any door enclosures or zippers.
      • 3. Inspect charger cords and receptacles for cracks, loose connections and frayed wiring. Replace any damaged components promptly.
      • 4. Always connect the charger to the vehicle first, then plug the charger into a wall receptacle. Make sure each charger uses a dedicated circuit to prevent overloading.
      • 5. When disconnecting the charger, always disconnect the charger from the wall receptacle first, then disconnect the charger from the vehicle.
• MAINTENANCE
  • Batteries
    • Battery Fluid
    • Battery Cell Cover
• SPECIFICATIONS
• POLARIS PRODUCTS
  • Gearcase / Transmission Lubricants
  • 2873602
  • Premium AGL Synthetic Gearcase Lubricant (qt.)
  • 2870465
  • Pump for Gallon Jug
  • Grease / Specialized Lubricants
  • 2871312
  • Grease Gun Kit, Premium All Season (3 oz.)
  • 2871322
  • Premium All Season Grease (3 oz. cartridge)
  • 2871423
  • Premium All Season Grease (14 oz. cartridge)
  • 2871515
  • Premium U-Joint Lube (3 oz.)
  • 2871551
  • Premium U-Joint Lube (14 oz.)
  • 2871329
  • Dielectric Grease (NyogelTM)
  • Additives / Miscellaneous
  • 2871956
  • LoctiteTM 565 Thread Sealant
• TROUBLESHOOTING
  • Vehicle Doesn’t Operate
• WARRANTY
  • LIMITED WARRANTY
  • REGISTRATION
  • WARRANTY COVERAGE AND EXCLUSIONS:
  • are not compatible with the vehicle. The exclusive remedy for breach of this warranty shall be, at Polaris' exclusive option, re...
• WARRANTY
  • LIMITATIONS OF WARRANTIES AND REMEDIES
• WARRANTY
  • LIMITATIONS OF WARRANTIES AND REMEDIES
  • HOW TO OBTAIN WARRANTY SERVICE
  • Lubricants
• WARRANTY
  • Exported Vehicles
  • How to Get Service
• WARRANTY
  • Notice
• MAINTENANCE LOG
  • DATE
  • MILES (KM)
  • OR HOURS
  • TECHNICIAN
  • SERVICE PERFORMED / COMMENTS
  • Battery Compartment Under Seat
  • Drink Rail
  • Charging Receptacle
• 9922699IX.pdf
  • INDEX
    • A
    • B
    • C
    • D
    • E
    • F
    • H
    • I
    • K
    • L
    • M
    • N
    • O
  • INDEX
    • P
    • R
    • S
    • S
    • T
    • V
    • W