Polaris X2 User Manual

ALWAYS USEAN APPROVEDHELMET ANDPROTECTIVE GEARFOR OPERATORAND PASSENGERNEVER USEON PUBLICROADSNEVER CARRYMORE THANONEPASSENGERNEVER USEWITH DRUGSOR AL

97MAINTENANCELightsWhen servicing a halogen lamp, don’t touch the lamp with barefingers. Oil from your skin leaves a residue, causing a hot spot thatw

98MAINTENANCELightsHigh Beam AdjustmentThe headlight beam can be adjusted slightly upward or downward.Use the following procedure to make the adjustme

99MAINTENANCELightsHeadlight Housin g Replacement1. Remove the two screws on the lower front corners of the headlightpod.2. Lift the pod slightly whil

121100MAINTENANCELightsLower Headlamp Removal / Installation1. Turn the back of the headlightharness (1) counterclockwiseand pull the harness assembly

101MAINTENANCESpark PlugsAlways use the spark plugs recommended for your ATV. Refer to thespecifications section beginning on page 122 for the recomme

102MAINTENANCEVehicle ImmersionCAUTIONIf your vehicle becomes immersed, major engine damage canresult if the machine is not thoroughly inspected. Take

103MAINTENANCESpark ArrestorWARNINGFailure to heed the following warnings while servicing the sparkarrestor could result in serious injury or death.Do

104MAINTENANCEPVT SystemThe basic operation of the Polaris PVT system is dependent on enginespeed and vehicle torque requirements. As engine speed inc

105MAINTENANCEPVT SystemWARNINGFailure to comply with the instructions in this warning can result insevere injury or death.Do not modify any component

106MAINTENANCEBatteryYour ATV may have either a sealed battery, which requires littlemaintenance, or a conventional battery. A sealed battery can beid

8SAFETYSafety Decals and LocationsWARNINGIMPROPER TIRE PRESSURE OR OVERLOADING can cause loss ofcontrol resulting in SEVERE INJURY OR DEATH.TIRE PRESS

107MAINTENANCEBatteryBattery Removal1. Disconnect the hold-down strap holding the battery in position, andremove battery cover.2. On conventional batt

108MAINTENANCEBatteryBattery StorageWhen the vehicle is placed in storage for three months or more, thebattery should be removed, stored out of the su

109MAINTENANCEBatteryBattery Charging (Sealed Battery)For a refresh charge, follow all instructions carefully.1. Check the battery voltage with a volt

110MAINTENANCEAccessoriesAuxiliary power outlets provide 12V power for operating accessoriessuch as hand held spot lights. Accessory outlets are avail

111MAINTENANCECleaning and StorageStorage TipsCAUTIONStarting the engine during the storage period will disturb theprotective film created by fogging

112MAINTENANCECleaning and StorageStorage TipsFog the Engine1. Treat the fuel system with Polaris Carbon Clean, following theinstructions on the can.

113MAINTENANCECleaning and StorageStorage TipsInspect and LubricateInspect all cables and lubricate. Follow lubrication guidelines in theMaintenance S

114MAINTENANCETransporting the ATVFollow these procedures whentransporting the vehicle.1. Turn off the engine andremove the key to preventloss during

115ADJUSTMENTSCamber and CasterThe camber and caster are non-adjustable.Rear SpringThe rear shock absorber spring isadjusted by rotating the adjuster

123116ADJUSTMENTSThrottle Body/Idle RPMIdle RPM is preset by the manufacturer. If the engine idle speed is notsatisfactory, please see your Polaris de

9SAFETYSafety Decals and LocationsWARNINGOperating this vehicle if you are under theage of 16 increases your chance of severeinjury or death.NEVER ope

117POLARIS PRODUCTSPart No. DescriptionEngine Lubricant2870791 Fogging Oil (12 oz. Aerosol)2871281 Premium 4 Synthetic 0W-40 (4-Cycle) Engine Oil (qt.

118TROUBLESHOOTINGContact your P olaris dealer for service if you’re unable to identifysolutions using the following charts.Drive Belt and Cover Probl

119TROUBLESHOOTINGEngine Doesn’t Turn OverPossible Cause SolutionLow battery voltage Recharge battery to 12.5 VDCLoose battery connections Check all c

120TROUBLESHOOTINGEngine Pings or KnocksPossible Cause SolutionPoor quality or low octane fuel Replace with recommended fuelIncorrect ignition timing

121TROUBLESHOOTINGEngine Stops or Loses PowerPossible Cause SolutionOut of fuel RefuelKinked or plugged fuel vent line Inspect and replaceWater presen

122SPECIFICATIONSSPORTSMAN X2 500 EFIGross Vehicle Weight 1500 lbs./680 kgHitch Towing Rating 1225 lbs./556 kgUnbraked Traile

123SPECIFICATIONSSPORTSMAN X2 500 EFIShift Type Side Lever (H/L/N/R/P)Gear Reduction - Low 23.91/1Gear Reduction - Reverse 21.74/1Gear Reduction - For

124WARRANTYLIMITED WARRANTYPolaris Sales Inc., 2100 Highway 55, Medina, MN 55340, gives a SIXMONTH LIMITED WARRANTY on all components of the Polaris A

125WARRANTYWARRANTY COVERAGE AND EXCLUSIONS:LIMITATIONS OF WARRANTIES AND REMEDIESThe Polaris limited warranty excludes any failures that are not caus

126WARRANTYALL IMPLIED WARRANTIES (INCLUDING BUT NOT LIMITEDTO THE IMPLIED WARRANTIES OF MERCHANTABILITY ANDFITNESS FOR A PARTICULAR PURPOSE) ARE LIMI

NEVER CARRYA PASSENGERUNDER AGE 12NEVER CARRYMORE THAN ONEPASSENGERNEVER RIDE AFTERUSING DRUGS ORALCOHOLHPASSENGERUNDER1210SAFETYSafety Decals and Loc

127WARRANTYExported VehiclesEXCEPT WHERE SPECIFICALLY REQUIRED BY LAW, THEREIS NO WARRANTY OR SERVICE BULLETIN COVERAGE ONTHIS VEHICLE IF IT IS SOLD O

128WARRANTYExported VehiclesHow to Get ServiceIf Purchased F rom A Private Party:If you purchase a Polaris product from a private citizen outside of t

129WARRANTYU.S.A. EPA Emissions Limited W arrantyThis All Terrain Vehicle (ATV) or Off Road Utility Vehicle (ORUV) emissions limitedwarranty is in add

130MAINTENANCE LOGUse the following chart to record periodic maintenance.DATE MILES (KM) TECHNICIAN SERVICE PERFORMED / COMMENTS

131MAINTENANCE LOGDATE MILES (KM) TECHNICIAN SERVICE PERFORMED / COMMENTS

132INDEXAAccessories 110...Adjustments 115-116...Age Restrictions 12...Air Filter Service 96...All W

133INDEXMMain Switch 36...Maintenance 74-114...Maintenance Chart 74-78...Maintenance Log 130-131...Making Tu

I11SAFETYSafety Decals and LocationsWARNINGS Moving parts hazard under belt-clutch guard. Toprevent serious injury, do not operate vehicle withgu ard

12SAFETYSafety TrainingATV safety training is a top priority for Polaris. When you purchasedyour new ATV, your dealer instructed you on the authorized

13SAFETYSafe Riding GearAlways wear clothing suited to t he type of riding. ATV riding requiresspecial protective clothing for comfort and to reduce t

14SAFETYRider SafetyWARNINGFailure to follow the warnings contained in this manual can resultin serious injury or death.A Polaris ATV is not a toy and

15SAFETYRider SafetyWARNINGSerious injury or death can result if you do not follow theseinstructions and procedures, which are outlined in further det

16SAFETYRider SafetyS Never operate at excessive speeds. T ravel at speeds appropriate foryour skills, your passenger’s skills, and operating conditio

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17SAFETYRider SafetyS Always use proper procedures if you stall or roll backwards whileclimbing a hill. To avoid stalling, maintain a steady speed whe

18SAFETYRider SafetyEquipment ModificationsWe are concerned for the safety of our customers and for the generalpublic. Therefore, we strongly recommen

19SAFETYRider SafetyWARNINGPOTENTIAL HAZARDOperating this ATV without proper instruction.WHAT CANHAPPENThe risk of an accident is greatly increased if

20SAFETYRider SafetyWARNINGPOTENTIAL HAZARDOperating with more than one passenger.WHAT CANHAPPENPassengers affect balance andsteering and increase the

21SAFETYRider SafetyWARNINGPOTENTIAL HAZARDOperating an ATV on pavedsurfaces, including sidewalks,paths, parking lots, and driveways.WHAT CANHAPPENATV

22SAFETYRider SafetyWARNINGPOTENTIAL HAZARDRiding an ATV withoutwearing an approvedhelmet, eye protection andprotective clothing.WHAT CANHAPPENRiding

5040010203023SAFETYRider SafetyWARNINGPOTENTIAL HAZARDRiding the ATV after consuming alcoholor drugs.WHAT CANHAPPENConsumption of alcohol and/or drugs

24SAFETYRider SafetyWARNINGPOTENTIAL HAZARDAttempting wheelies, jumpsand other stunts.WHAT CANHAPPENAttempting stunts increasesthe chance of an accide

25SAFETYRider SafetyWARNINGPOTENTIAL HAZARDOperating on frozen bodies of water.WHAT CANHAPPENSevere injury or death can result if the ATV and/or the o

26SAFETYRider SafetyWARNINGPOTENTIAL HAZARDFailure to use extracaution when operatingthe ATV on unfamiliarterrain.WHAT CANHAPPENUnfamiliar terrain may

A card containing important ATV safety information should be attachedto the owner’s manual on the next page. If you cannot locate this card,or if it h

>15_27SAFETYRider SafetyWARNINGPOTENTIAL HAZARDT urning improperly.WHAT CANHAPPENImproper turns could cause loss of control and lead to a collision

28SAFETYRider SafetyWARNINGPOTENTIAL HAZARDClimbing hills improperly.WHAT CANHAPPENImproper hill climbingcould cause loss ofcontrol or overturn.HOW TO

29SAFETYRider SafetyWARNINGPOTENTIAL HAZARDT raveling downhillimproperly.WHAT CANHAPPENImproperlydescending a hillcould cause loss ofcontrol or overtu

30SAFETYRider SafetyWARNINGPOTENTIAL HAZARDImproperly crossing hills andturning on hills.WHAT CANHAPPENImproperly crossing orturning as hills could ca

31SAFETYRider SafetyWARNINGPOTENTIAL HAZARDStalling, rolling backwardsor improperly dismountingwhile climbing a hill.WHAT CANHAPPENThe vehicle could o

32SAFETYRider SafetyWARNINGPOTENTIAL HAZARDImproperly operating over obstacles.WHAT CANHAPPENOperating over obstacles could cause loss of control or o

33SAFETYRider SafetyWARNINGPOTENTIAL HAZARDOperating the ATV through deep or fast-flowing water.WHAT CANHAPPENT ires may float, causing loss of tracti

34SAFETYRider SafetyWARNINGPOTENTIAL HAZARDOperating the ATV with improper modifications.WHAT CANHAPPENImproper installation of accessories or modific

35SAFETYRider SafetyWARNINGLeaving the keys in the ignition can lead to unauthorized use ofthe vehicle resulting in serious injury or death. Always re

36CONTROLSEngine Electrical SwitchesWARNINGActivating the override switch while the throttle is open can causeloss of control, resulting in severe inj

1WELCOMEThank you for purchasing a Polaris vehicle, and welcome to ourworld-wide family of P olaris owners. We proudly produce an excitingline of util

137CONTROLSWARNINGOperating an ATV with sticking or improperly operating throttlecontrols could cause an accident and lead to severe injury ordeath.Ne

38CONTROLSLight SwitchesThe light switch is located on the left handlebar. It’s used to turn thelights on and off and to switch the lights from HI to

39CONTROLSMaster CylinderThe brake fluid in the mastercylinder (1), which is located on theleft handlebar, should be checkedbefore each ride. The flui

40CONTROLSParking BrakeWARNINGOperating the ATV while the parking brake is engaged couldresult in an accident and serious injury or death. Always chec

41CONTROLSAuxiliary BrakeWARNINGAggressively applying the auxiliary brake when backing down ahill may cause rear tipover, which could result in seriou

HNPLR142CONTROLSAutomatic Transmission Gear SelectorThe transmission gearselector (1) is located onthe right side of thevehicle.H: High GearL: Low Gea

43FEATURESAll Wheel Drive (AWD) SystemThe AWD system is activatedby a switch (1) on the righthandlebar.When the switch is on 2X4(center position), the

44FEATURESAll Wheel Drive (AWD) SystemEngaging Front GearcaseThe AWD switch may be turned on or off while the vehicle is moving.Initially, the vehicle

45FEATURESPassenger Seat4. Continue lifting thebackrest latch while loweringthe backrest to create thepassenger seat (D).5. Release the backrest latch

46FEATURESInstrument ClusterYour ATV is equipped with an instrument cluster that senses vehiclespeed from the right front wheel. The instrument cluste

2Copyright 2005 Polaris Sales Inc. All information contained within this publication isbased on the latest product information at the time of publicat

47FEATURESInstrument ClusterRider Information CenterThe rider information center is located in the instrument cluster. Allsegments will light up for 2

48FEATURESInstrument ClusterRider Information CenterThe rider information center has 4 standard modes:Mode 1 - OdometerMode 2 - TripmeterMode 3 - Tota

49FEATURESInstrument ClusterRider Information CenterDiagnostic ModeThe diagnostic mode is for informational purposes only. P l ease returnyour ATV to

50FEATURESInstrument ClusterRider Information CenterDiagnostic ModeScreen 5: P rogrammable service intervalThe purpose of the programmable service int

51FEATURESInstrument ClusterRider Information CenterSpecial EFI Diagnostic ModeThe EFI diagnostic mode is for informational purposes only. Pleasesee y

52OPERATIONFuel SafetyWARNINGGasoline is highly flammable and explosive under certainconditions.S Always exercise extreme caution whenever handling ga

53OPERATIONBreak-In PeriodThe break-in period for your new Polaris ATV is the first ten hours ofoperation, or the time it takes to use the first two f

54OPERATIONPre-Ride InspectionWARNINGIf a proper inspection is not done before each use, severe injuryor death could result. Always inspect the vehicl

55OPERATIONStarting the EngineWARNINGEngine exhaust contains poisonous carbon monoxide and cancause loss of consciousness resulting in severe injury o

56OPERATIONDriving Procedures1. Wear appropriate ridinggear. See page 13.2. Perform the pre-rideinspection. See page 54.3. Place thetransmission inPAR

3TABLE OF CONTENTSVEHICLE IDENTIFICATION NUMBERS 5...SAFETY 6...CONTROLS 36...FEATURES

57OPERATIONMaking TurnsBoth rear wheels drive equally atall times, except when operating inTURF mode. This means that theoutside wheel must travel a g

58OPERATIONDriving with a Passenger1. Make sure the passenger is atleast 12 years of age and is tallenough to comfortably reach thefootrests and grab

59OPERATIONDriving with a Passenger10. Ride to the ability of your passenger, instead of to your ownability. Avoid unexpected or aggressive maneuvers

60OPERATIONDriving on Slippery SurfacesWhenever riding on slipperysurfaces such as wet trails orloose gravel, or duringfreezing weather, follow thesep

61OPERATIONDriving UphillWhenever traveling uphill, follow these precautions:1. Always travel straight uphill.2. Avoid steep hills (15_ maximum).3. Ke

62OPERATIONDriving on a HillsideWARNINGImproperly crossing hills or turning on hills can result in loss ofcontrol or vehicle overturn, resulting in se

63OPERATIONDriving DownhillWhenever descending a hill, follow these precautions:1. Always descend a hill with the t ransmission in forward gear. Donot

8’ (2.4 m)64OPERATIONTurning Around on a HillIf the vehicle stalls while climbing a hill, never back it down the hill!Use the K-turn to turn around.

65OPERATIONTurning Around on a Hill1. Stop the vehicle and lock the parking brake while keeping bodyweight uphill.2. Leave the transmission in forward

66OPERATIONDriving Through WaterYour ATV can operatethrough water with amaximumrecommended depthequal to the bottomof the footrests (1).Follow thesepr

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67OPERATIONDriving Through WaterCAUTIONMajor engine damage can result if the vehicle is not thoroughlyinspected after operation in water . Perform the

68OPERATIONDriving in ReverseFollow these precautions whenoperatinginreverse:1. Always avoid backingdownhill.2. Always check for obstaclesor people be

69OPERATIONDriving Over Obstacles1. Be alert! Look ahead and learnto read the terrain you’retraveling on. Be constantlyalert for hazardssuch as logs,

70OPERATIONHauling CargoWARNINGOverloading the vehicle or carrying or towing cargo improperlycan alter vehicle handling and may cause loss of control

71OPERATIONHauling CargoLoad DistributionYour ATV has been designed tocarry or tow a certain amount ofload. Always read andunderstand the load distrib

72OPERATIONHauling CargoDumping Cargo1. Select a level site to dump the cargo box. Do not attempt to dumpor unload the vehicle while parked on an incl

73EMISSION CONTROL SYSTEMSNoise Emission Control SystemDo not modify the engine, i ntake or exhaust components, as doing somay affect compliance with

74MAINTENANCEPeriodic Maintenance ChartCareful periodic maintenance will help keep your vehicle in the safest,most reliable condition. Inspection, adj

75MAINTENANCEPeriodic Maintenance ChartMaintenance Chart Key" Perform these procedures more frequently for vehicles subjected tosevere use.E Emis

76MAINTENANCEPeriodic Maintenance ChartPerform all services at whichever maintenance interval is reached first.Item Maintenance Interval(whichever com

5VEHICLE IDENTIFICATION NUMBERSRecord your ATV’s identification numbers and key number in thespaces provided. Remove the spare key and store it in a s

77MAINTENANCEPeriodic Maintenance ChartItem Maintenance Interval(whichever comes first)RemarksHours Calendar Miles(Km)"Generallubrication50 H 3M

78MAINTENANCEPeriodic Maintenance ChartItem Maintenance Interval(whichever comes first)RemarksHours Calendar Miles(Km)JClutches (driveand driven)100 H

79MAINTENANCELubrication GuideCheck and lubricate all components at the intervals outlined in thePeriodic Maintenance Chart beginning on page 74. Item

80MAINTENANCEPremium 4 Synthetic LubricantPolaris Premium 4 All Season synthetic engine oil has been speciallyformulated for use in P olaris 4-cycle e

1ADD 8 OZ. NORMAL FULL281MAINTENANCEOil LevelThe oil dipstick and fill tube (1) are located on the left side of the ATV.NOTE: A rising oil level betwe

82MAINTENANCEOil and Filter ChangeChange the oil and filter at t he intervals outlined in the PeriodicMaintenance Chart beginning on page 74.1. Positi

83MAINTENANCEOil Change10. Place shop towels beneath t he oil filter. Using an oil filter wrench,turn the filter (1) counterclockwise and remove.11. L

84MAINTENANCEOil ChangeOil Pump PrimingThis priming procedure must beperformed whenever the oil hoseconnection between the oil tankand pump inlet has

85MAINTENANCETransmission OilAlways check and change the transmission oil at the intervals outlinedin the Periodic Maintenance Chart beginning on page

86MAINTENANCETransmission OilOil ChangeThe transmission drain plug (2) is located on the right side of thegearcase, on the right side of the ATV, behi

6SAFETYSafety Decals and LocationsWarning decals have been placed on the ATV for your protection. Readand follow the instructions of the decals on the

87MAINTENANCEFront Gearcase OilAlways check and change the front gearcase oil at the intervalsoutlined in the Periodic Maintenance Chart beginning on

88MAINTENANCEEngine Cooling SystemRadiator Coolant LevelTo ensure that the coolant maintains its ability to protect the engine, werecommend that the s

89MAINTENANCEEngine Cooling SystemCoolant LevelThe recovery bottle (1) is locatedon the left side of the machine. Toaccess the recovery bottle, remove

90MAINTENANCEBrakesThe front and rear brakes are hydraulic disc brakes, activated bymoving the single brake lever toward the handlebar. These brakes a

91MAINTENANCEBrakes2. Check the brake system for fluid leaks.3. Check the brakes for excessive travel orspongy feel.4. Check the friction pads for wea

92MAINTENANCESteering AssemblyThe steering assembly of the ATV should be checked periodically forloose nuts and bolts. If l oose nuts and bolts are fo

93MAINTENANCESide Panel Removal1. Remove the seat.2. Grasp the rear of the side panel near the rear cab. With a firmmotion, pull the panel outward to

94MAINTENANCEWARNINGOperating your ATV with worn tires, improperly inflated tires,non-standard tires or improperly installed tires will affect vehicle

95MAINTENANCEWheel InstallationWARNINGImproperly installed wheels can adversely affect tire wear andvehicle handling, which can result in serious inju

96MAINTENANCEFilter SystemsAir Filter Service1. Remove the seat, release theair box cover clips, andremove the air box cover.2. Loosen the clamp and r