Polaris 570 manual

Owner's Manual for Maintenance and Safet y Read this manual carefully . It contains important safety information. This is an adult vehicle only . Operation is prohibited for those under 16 years of age. Spor tsman Forest 5 70[...]

1 WELCOME Thank you for purchasing a POLARIS vehicle, and welcome to our world-wide family of POLARIS enthusiasts. Be sure to visit us online at www .polaris.com for the latest news, new product introductions, upcoming events, career opportunities and more. Here at POLARIS we proudly produce an exciting line of utility and recreational products. ?[...]

2 POLARIS® and SPOR TSMAN® are registered trademarks of POLARIS Industries Inc. Copyright 2013 POLARIS Sales Inc. All information contained within this publication is based on the latest product information at the time of publication. Due to constant improvements in the design and quality of production components, some minor discrepancies may res[...]

3 T ABLE OF CONTENTS Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Features and Controls . . . . . . . . . . . . . . . . . . . 20 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 Winch Guide . . . . . . . . . . . . . . . . . . .[...]

4 INTRODUCTION The following signal words and symbol s appear througho ut this manual and on your vehicle. Y our safety is involved when these words and symbols are used. Become familiar with their meanings before reading the manual. The safety alert symb ol ind icates a potential personal injury hazard. DANGER A DANGER indicates a hazardous situat[...]

5 INTRODUCTION Failure to heed the warnings and safety pre cautions contained in this manu al can result in severe injury or death. A POLARIS A TV is not a toy and can be hazardous to operate. Thi s vehicle handles differently than other vehicles, su ch as motorcycles and cars. A collision or rollover can occur quickly , even during routine maneuve[...]

6 INTRODUCTION V ehicle Identification Numbers Record your vehicle's identification numbers and key number in the spaces provided. Remove the spare key and store it in a safe place. An ignition key can be duplicated only by ordering a POLARI S key blank (using your key number) and mating it with one of your existing keys. The ignition switch m[...]

7 INTRODUCTION European Vi bration and Noise The driver -perceived noise and hand/arm and whole body vibration levels of this machinery is measured per prEN 15997. The operating conditions of the machinery during testing: The vehicles were in like-new condition. The environment was controlled as indicated by the test procedure(s). The uncertainty o[...]

8 SAFETY Safety T raining Never operate this vehicle without proper instruction. T ake a training course. For more information about safety , contact an authorized POLARIS dealer or visit the POLARIS web site at www .polaris.com. Safe Riding Gear Always wear appropriate clothing when riding an A TV . W ear protective clothing for comfort and to red[...]

9 SAFETY Safe Riding Gear Eye Protection Do not depend on eyeglasses or sunglasses for eye protection. Whenever riding a POLARIS veh icle, always wear shatterproof goggles or use a shatterproof helmet face shield. POLARIS recommends wearing approved Personal Prot ective Equipment (PPE) bearing markings such as VESC 8, V -8, Z8 7.1, or CE. Make sure[...]

10 SAFETY Operator Safety Serious injury or death can result if you do not follow the instructions and procedures listed here and th roug hout this manual. Read and understand all warnings, cautions and operating procedures in this manual and on the safety labels before operating the vehicle. Never operate this vehicle without proper instruction. T[...]

11 SAFETY Operator Safety Always wear an approved helmet that fits properly . Wear eye protection (goggles or face shield), gloves, boots, long sleeve s and long pan ts. Never consume alcohol o r drugs before or while operating this vehicle. Never operate at excessive speeds. Travel and turn at speed s appropriate for the terrain, visibility , oper[...]

12 SAFETY Operator Safety Always inspect your POLARIS vehicle before each use to verify that it's in safe operating condition. Follow the inspection and maintenance procedures outlined in this manual. See page 40. Keep both hands on the handleba rs. Keep your feet on the footrests. Always travel slowly when operati ng on unfamiliar terrain. Us[...]

13 SAFETY Operator Safety If the vehicle has been involved in an accide nt, alw ays have an authorized POLARIS dealer inspect the entire vehicle for possible damage, incl udin g (but not limited to) brake, throttle and steering system s. Never operate on hills too steep for the vehicle or for your abilities. Practice on smaller hills before attempt[...]

14 SAFETY Operator Safety Always follow the procedures outlined in this manual for braking if you stall or roll backwards while climbing a hill. Never back down a hil l. See page 48. Always follow the procedures outlined in thi s manual for operating over obstacles. See p age 51. Always follow the procedures outlined i n this manual for operating o[...]

15 SAFETY Operator Safety Always follow the procedures outlined in thi s manual for driving in reverse. See page 54. Always use the size and type of tires specified for your vehicle. Maintain the proper tire pressure. Never modify this POLARIS vehicle through improper installation or use of accessories. Never exceed the stated load capacity for you[...]

16 SAFETY Operator Safety Never operate the ve hicle on a frozen body of water unless you have independently verified that the ice is sufficiently thick to support the weight and moving force of the vehicle, you and your cargo, together with any other vehicles in your party . Operating on paved surfaces may affect the handling and control of the ve[...]

17 SAFETY Safety Labels and Locations W arning labels have been placed on the vehicle for your protection. Read and follow the instructions on each label carefully . If a label becomes illegible or comes of f, contact your POLARIS dealer to pur- chase a replacement. Replacement safety labels are provided by POLARIS at no char ge. The part number is[...]

18 SAFETY Safety Labels and Locations “No Passenger” W arning W ARNING - NEVER ride as a passenger . Passengers can caus e a loss of control, resulting in SEVERE INJUR Y or DEA TH. Tire Pre ssure/Load Alert TIRE PRESSURE IN PSI (KPa): FRONT 5 (34.5) REAR 5 (34.5) MAXIMUM WEIGHT CAP ACITY (Gross V ehicle Weight) INCLUDING MACHINE, DRIVER AND CAR[...]

19 SAFETY Safety Labels and Locations Clutch Cover W arning W ARNING • Moving parts hazard under belt-clutch guard. T o prevent serious injury , do not operate vehicle wi th guard removed. • Do not modify engine or clutch. Doing so can cause pa rt failure, possible imbalance, and excessive engine RPM, whi ch can re sult in seriou s injury or de[...]

20 FEA TURES AND CONTROLS Switches Engine Stop Switch The engine will not start or run when the switch is in the OFF position. OFF RUN Push the stop switch down to stop the engine quickly . Pull the stop switch up to the RUN position before attempting to start the engine. Both the main switch and the engine stop switch will shut off all electrical [...]

21 FEA TURES AND CONTROLS Switches Headlight Switch The lights do not operate unless the main key switch is on and the engine stop switch is in the RUN position. High Beam Low Beam T urn Signal Switch Push the toggle switch either left or right to activate the corre- sponding turn signal light. The indicator on the pod will also flash. Return the t[...]

22 FEA TURES AND CONTROLS Switches Moment ary High Beam Switch Press this switch with your left forefinger to activate the headlight high beam. The lights will return to low beam when the switch is released. Winch Switch See page 58 for winch information. Main Key Switch End all electrical power to the vehicle. LIGHTS ON position turns the headligh[...]

23 FEA TURES AND CONTROLS Throttle Lever Failure to check or maintain proper opera tion of the throttle system can resul t in an accident if the throttle lever sticks during operation. Check th e lever fo r proper operation before starting the e ngine. Check occasionally during operation. Do not start or operate a vehicle with sticking or improperl[...]

24 FEA TURES AND CONTROLS Foot Brake The all-wheel foot brake is located on the right footrest. The foot brake operates both front and rear brakes. Press the brake pedal down with your foot to apply the all-wheel brakes. If the rear wheels begin to skid or slide while using the foot brake, reduce brake pressure. Hand Brake Lever The hand brake oper[...]

25 FEA TURES AND CONTROLS Parking Brake Locking the Parking Brake 1. Place the transmission in PA R K . 2. Squeeze the brake lever toward the handlebar . 3. Push the parking brake lock forward to engage the lock. 4. Release the brake lever . 5. T o release the parking brake lock, squeeze and release the brake lever . Operating the vehicle while the[...]

26 FEA TURES AND CONTROLS Fuel T ank Cap This vehicle is equipped with a digital fuel gauge that will indicate a low fuel condition. Refuel when the gauge indicates a low fuel condition. Always refuel with the engine stopped, and outdoors or in a well ventilated area. Refuel on a level surface. Remove the fuel tank cap to add fuel to the fuel tank.[...]

27 FEA TURES AND CONTROLS All Wheel Drive System The All Wheel Drive sy stem is controlled by the 4X4 switch. 4X4 Mode When the switch is on 4X4, the A TV is in 4X4, and the 4X4 indicator icon in the instrument cluster display will be visible. When in 4X4, the demand drive unit will automatically engage any time the rear wheels lose traction. When [...]

28 FEA TURES AND CONTROLS Instrument Cluster NOTICE: High water pressure may d amage A TV components. Wa sh the A TV by hand or with a garden hose using mild soap. Certain products, including insect repellents and chemicals, will damage the speedometer len s and other plasti c surfaces. Do not us e alcohol to clean the instrument cluster . Do not a[...]

29 FEA TURES AND CONTROLS Instrument Cluster Digit al/Analog Gauge Indicator Lamp s Lamp Indicates Condition V ehicle S p eed When standard mode is selected, speed displays in miles per hour . When metric mode is selected, speed displays in kilometers per hour . Over T emperature Thi s lamp flashes to indicate an overheated engine. If the indicator[...]

30 FEA TURES AND CONTROLS Instrument Cluster Digit al/Analog Gauge Rider Information Center The rider information center is located in the instrument cluster . All segments will light up for one second at start-up. If the instrument cluster fails to illuminate, a battery over-voltage may have occurred and the instrument cluster may have shut of f t[...]

31 FEA TURES AND CONTROLS Instrument Cluster Digit al/Analog Gauge Rider Information Center 1. Gear Display - This area displays gear shifter position: H = High Gear L = Low Gear N = Neutral R = Reverse Gear P = Park -- = Gear Signal Error (or shifter between gears) 2. Fuel Gauge Display - The segments of the fuel gauge show the level of fuel in th[...]

32 FEA TURES AND CONTROLS Instrument Cluster Digit al/Analog Gauge Rider Information Center The reverse override button acts as the MODE button when pressed and released quickly . The transmission cannot be in reverse when using the override button as a MODE button. This feature does not contain a vehicle speed lockout function and can be used at a[...]

33 FEA TURES AND CONTROLS Instrument Cluster Digit al/Analog Gauge Rider Information Center Clock Mode Tip : The clock must be reset any time the battery has been disconnected or discharged. 1. T urn the key to the ON position. Use the MODE button to toggle to the odometer display . 2. Press and hold the MODE button until the hour segment flashes. [...]

34 FEA TURES AND CONTROLS Instrument Cluster Digit al/Analog Gauge Rider Information Center Programmable Service Interval When the hours of engine oper ation equal the programmed service interval setting, the wrench icon will flash for 5 seconds each time the engine is started. When this feature is enabled, it provides a convenient reminder to perf[...]

35 FEA TURES AND CONTROLS Instrument Cluster Digit al/Analog Gauge Rider Information Center Engine Error Codes The error screen displays only when the CHECK ENGINE light is on or when it goes on and off during one ignition cycle. Error codes are not stored in the gauge when the key is turned off. The code and message is lost, but will reappear if t[...]

36 FEA TURES AND CONTROLS Instrument Cluster Diagnostic Display Code Definitions Open Load : There is a break in the wires that lead to the item listed in the chart (injector , fuel pump, etc.), or the item has failed. Short-to-Gr ound : The wire is shorted to ground between the electronic control unit and the item listed in the chart. Shorted Load[...]

37 FEA TURES AND CONTROLS Instrument Cluster Diagnostic Display Code Definitions *Assumes unipolar configuration of ste ppe r motor SPORTSMAN 570 EFI/570 EPS Diagnostic Codes Component Condition SPN FMI Idle Air Control Driver Circuit Grounded 520193 5 Shorted Load* 520193 1 1 S tarter Enable Circuit Driver Circuit Short to B+ 1321 3 All Wheel Driv[...]

38 OPERA TION Failure to operate the A TV properly can resul t in a coll ision , loss of control, accident or rollover , which may result in serious injury o r death. Read and understand all safety warnings outlined in the safety section of this owner ’s manual. Break-In Period The break-in period for your new POLARIS A TV is the first 20 hours o[...]

39 OPERA TION Break-In Period Engine and Drivetrain Break-in 1. Fill the fuel tank with gasoline. See page 26. Always exercise extreme caution whenever handling gasoline. 2. Check the oil level on the dipstick. See page 77. Add oil if necessary to maintain the level between the safe and add marks. 3. Drive slowly at first. Select an open area that [...]

40 OPERA TION Pre-Ride Checklist Failure to inspect and verify that the A TV is in safe operating condition before operating increases the risk of an accident. Always inspect the A TV before each use to make sure it's in safe operating condition. Item Remarks Page Foot brake Ensure proper operation 24 Hand brake/lever travel Ensure proper oper[...]

41 OPERA TION S t arting the Engine Engine exhaust contains poisonous carbon monoxide and can cause loss of consciousness resulting in severe injury or death. Never run an engine in an enclosed area. 1. Position the vehicle on a level surface outdoors or in a well- ventilated area. 2. Place the transmission in P ARK. Tip : The starter interlock wil[...]

42 OPERA TION Driving Procedures 1. W ear a helmet and eye protection. See page 8. 2. Sit upright with both feet on the foo trests and both hands on the handlebars. 3. Star t the engine and allow it to warm up. 4. Shift the transmission into gear . 5. Check your surroundings and determine your path of travel. 6. Slowly depress the throttle with you[...]

43 OPERA TION T urning the V ehicle 1. Before turning, activate a turn signal to alert others of your intentions. Activate the left signal before a left turn. Activate the right signal before a right turn. 2. Steer in the direction of the turn, leaning your upper body to the inside of the turn while supporting your weight on the outer footrest. Use[...]

44 OPERA TION Driving Uphill Braking and handling are greatly af fected when operating in hilly terrain. Improper procedure could ca use loss of control or rollover . Whenever traveling uphill, follow these precautions: 1. Drive straight uphill. 2. A void steep hills (25° maximum). 3. Always check the terrain carefully before ascending any hill. 4[...]

45 OPERA TION Driving Safely Driving Uphill If all forward speed is lost: Keep your weight uphill. If the vehicle begins r olling downhill, never apply engine power . Never apply the brakes aggr essively while r olling backwar ds. Apply the brakes gradually . When fully stopped, lock the hydraulic parking brak e. See page 25. Dismount on the uphill[...]

46 OPERA TION Driving on a Sidehill (Sidehilling) Driving on a sidehill is not r ecommended. Improper procedure could cause loss of control or rollover . A void crossing the side of any hill unless absolutely necessary . If crossing a sidehill is unavoidable , follow these precautions: 1. Slow down. 2. A void crossing the side of a steep hill. 3. S[...]

47 OPERA TION Driving Downhill When driving downhill, follow these precautions: 1. Check the terrain carefully . 2. A void hills with excessively slippery or loose surfaces. 3. Never drive downhill at high speed. 4. Slow down. 5. A void driving downhill at an angle, which can cause the vehicle to pitch sharply to one side. Drive straight downhill. [...]

48 OPERA TION T urning Around on a Hill (K-T urn) If the vehicle stalls while climbing a hill, never back it down the hill! Use the K-turn to turn around. 1. Stop the vehicle. Keep your weight uphill. 2. Lock the hydraulic parking brake. 3. Leave the transmission in forward gear . Turn the engine of f. 4. Dismount on the uphill side of the vehicle,[...]

49 OPERA TION T urning Around on a Hill (K-T urn) 8. Lock the hydraulic parking brake. 9. Remount from the uphill side. Keep your weight uphill. 10. Apply the foot brake. 1 1. W ith the transmission still in forward, start the engine. 12. Squeeze and release the brake le ver to release the parking brake. 13. Release the foot brake and drive slowly [...]

50 OPERA TION Driving on Slippery Surfaces Whenever riding on slippery surfaces such as wet trails or loose gravel, or during freezing weather , follow these precautions: 1. Do not operate on excessively rough, slippery or loose terrain. 2. Slow down when entering slippery areas. 3. Engage 4X4 before wheels begin to lose traction. NOTICE: Severe da[...]

51 OPERA TION Driving Over Obst acles Follow these precautions when operating over obstacles: 1. Always check for obstacles before operating in a new area. Serious injury or death can result if your vehicle comes in contact with a hidden obstacle. 2. Be alert. W atch the terrain. Use extra caution. 3. Never operate over large obstacles. 4. A void h[...]

52 OPERA TION Driving Through W ater Follow these procedures when driving through water: 1. Check water depth and current before crossing. 2. A void operating in water deeper than the bottom of the footrests. If it's unavoidable, travel slowly , balance your weight carefully and avoid sudden movements. Maintain a slow and steady forward motion[...]

53 OPERA TION Driving Through W ater If your vehicle becomes fully immersed, and it's impossible to take it to a dealer before starting it, follow the steps described on page 102. Have the vehicle serviced by your dealer promptly . If water has been ingested into the transmission (PVT), follow the pro- cedure on page 102. Always follow the pro[...]

54 OPERA TION Driving in Reverse Follow these precautions when operating in reverse: 1. Always check for obstacles or people behind the vehicle. 2. Always avoid backing downhill. 3. Back slowly . 4. Apply the brakes lightly for stopping. 5. A void turning at sharp angles. 6. Never open the throttle suddenly . 7. Do not use the override button unles[...]

55 OPERA TION Parking on an Incline A void parking on an incline if possible. If it's unavoidable, follow these precautions: 1. Stop the engine. 2. Place the transmission in P ARK. 3. Always block the rear wheels on the downhill side.[...]

56 OPERA TION Hauling Cargo Overloading the vehicl e or carrying or tow ing cargo improperl y can alter vehicle handling and may cause loss of control or brake instability . Always follow thes e precautions when hauling cargo . • Read and understand the load distribution warnin gs listed on the vehicle warning labels. • Never exceed the stated [...]

57 OPERA TION Hauling Cargo T owing Loads T owing is approved OFF-ROAD ONL Y . Operating this vehicle with a trailer on public roads is prohibited. Do not exceed the maximum capac- ities when towing. Do not tow any trailer on a grade steeper than 15°. Unbraked T railer T owing Capacity is 1786 lbs. (810 kg) based on EU Directive 76/432/EC. Using a[...]

58 WINCH GUIDE These safety warnings and instructions apply if your vehicle came equipped with a winch or if you choose to add an accessory winch to your vehicle. Improper winch use can result in SEVERE INJURY or DEA TH. Always follow all winch instructions and warnings in this manual. Your winch may have a cable made of either wire rope or special[...]

59 WINCH GUIDE Winch Safety Precautions 1 1. Always align the vehicle and winch with the load directly in front of the vehicle as much as possible. A void winching with the winch cable at an ang le to the winching vehicle’ s centerline whenever possible. 12. If winching at an angle is unavoidable, follow these precautions: A. Look at the winch dr[...]

60 WINCH GUIDE Winch Safety Precautions 20. Never use the winch to hoist or suspend a vertical load. 21. Never immerse or submerse your winch in water . T ake your winch to your dealer for service if this occurs. 22. Always inspect your winch and winch cable before each use. 23. Never winch the hook fully into the winch. This can cause damage to wi[...]

61 WINCH GUIDE Winch Operation Read the W inch Safety Pr ecautions in the preceding pages before using your winch. Tip : Consider practicing the operation a nd use of your winch before you a ctually need to use it in the field. Improper winch use can result in SEVERE INJURY or DEA TH. Always follow all winch instructions and warnings in this manual[...]

62 WINCH GUIDE Winch Operation 4. Always use the hook strap when handling the hook. W ARNING! Never put your fi nge rs into the hook. This could lead to SEVERE INJURY . A. Attach the hook itself onto the load or use a tow strap or chain to secure the load to the winch cable. Tip : A “tow strap” is NOT intended to stretch. A “recovery strap”[...]

63 WINCH GUIDE Winch Operation 5. Never remove the hook strap from the hook. 6. Release the winch clutch and pull out the winch cable. 7. Pulling out as much cable as possible maximizes the winch’ s pulling capacity . Always be sure that at least five (5) full turns of winch cable are wrapped around the winch drum at all times. The friction provi[...]

64 WINCH GUIDE Winch Operation 1 1. The ONL Y time a winch-equipped vehicle should be moving when using the winch is when that vehicle itself is stuck. The winch- equipped vehicle should NEVER be in motion to “shock” load the winch cable in an attempt to move a second stuck vehicle. See the Shock Loading section on page 67. For your safety , al[...]

65 WINCH GUIDE Winch Operation 13. Extensive winching will run down the battery on the winching vehicle. Let the winching vehicle’ s engine run while operating the winch to prevent the battery from running low if winching for long periods. 14. The winch motor may become hot during winch use. If you winch for more than 45 seconds, or if the winch [...]

66 WINCH GUIDE Winch Cable Care For your safety , always replace POLARIS winch parts (including the cable) with genuine POLARIS replacement parts available at your authorized POLARIS dealer . W ARNING! Use of worn or damaged ca ble could lead to sudden failure and SEVERE INJUR Y . 1. Always inspect your winch before each use. Inspect for worn or lo[...]

67 WINCH GUIDE Shock Loading W ARNING! Y our winch cable is very strong but it is NOT designed for dynamic, or “shock” loading. Shock loading may tension a wi nch cable beyond its strength and cause the cable to brea k. The end of a broke n winch cable under such hig h loading can cause SEVERE INJUR Y or DEA TH to you and other bystanders. W in[...]

68 WINCH GUIDE Shock Loading 4. Never use recovery straps with your winch. Recovery straps are designed to stretch and can store ener gy . This stored energy in the recovery strap is released if a winch cable fails making the event even more hazardous. Similarly , never use elastic “bungie” cords for winching. 5. Never use the winch to tie down[...]

69 WINCH GUIDE Winch Maintenance and Service Safety W ARNING! Improper or lack of winch ma inten ance and service could lead to SEVERE INJUR Y or DEA TH. Always follow all winch instructions and warnings in this manual. 1. Always inspect your winch before each use. Inspect for worn or kinked winch cable. Also inspect for worn or loose parts includi[...]

70 EMISSION CONTROL SYSTEMS Noise Emission Control System Do not modify the engine, intake or exhaust components, as doing so may affect compliance with governmental noise level requirements. S p ark Arrester Y our POLARIS vehicle has a spark arrester that was designed for on- road and off-road operation. It is required that this spark arrester rem[...]

71 MAINTENANCE Periodic Maintenance Chart Careful periodic maintenance will help keep your vehicle in safe, reli- able condition. Inspect, clean, lubricate, adjust and replace parts as nec- essary . When inspection reveals th e need for replacement parts, use genuine POLARIS parts available from your POLARIS dealer . Record maintenance and service [...]

72 MAINTENANCE Periodic Maintenance Chart Maintenance Chart Key W ARNING! Improperly perf or ming th e procedures marked with a “D” could result in component failure and lead to serious injury or death. Have an authorized POLARIS dealer perform these services. Perform all services at whichever ma intenance interval is r eached first. Ź Perform[...]

73 MAINTENANCE Periodic Maintenance Chart Item Maintenance Interval (whichever comes first) Remarks Hours Calendar Miles (Km) Ź Air filter , main element - W eekly - Inspect; replace as needed Recoil housing - Weekly - Drain water as needed, check often if operating in wet conditions Ź D Brake pad wear 10 H Monthly 100 (160) Inspect periodically [...]

74 MAINTENANCE Periodic Maintenance Chart Ź Perform these procedures more often for vehicles subjected to severe use. D Have an authorized POLARIS dealer perform these services. Item Maintenance Interval (whichever comes first) Remarks Hours Calendar Miles (Km) Ź Demand drive fluid (normal use) 100 H 12 M 1000 (1600) Change fluid Ź Rear gearcase[...]

75 MAINTENANCE Lubrication Guide Check and lubricate all components at the intervals outlined in the Periodic Maintenance Chart beginning on page 71. Items not listed in the chart should be lubricated at the General Lubr ication interval. The a-arms and lower control arms are lubricated at the factory , and no additional lubrication will be needed.[...]

76 MAINTENANCE Engine Oil Oil Recommendations Always change the oil filter whenever changing oil. POLARIS recommends the use of POLARIS PS-4 Full Synthetic 5W - 50 4-cycle oil or a similar oil for this engine. Oil may need to be changed more frequently if POLARIS oil is not used. Always use 5W - 50 oil. Follow the manufacturer's recommendation[...]

77 MAINTENANCE Engine Oil Oil Level Access the oil dipstick and fill tube from the right side of the A TV . A rising oil level between checks in cool weather driving can indicate contaminants such as gas or moisture collecting in the crankcase. If the oil level is over the full/safe mark, change the oil immediately . 1. Position the vehicle on a le[...]

78 MAINTENANCE Engine Oil Oil and Filter Change Always change the oil and filter at the intervals outlined in the Periodic Maintenance Chart beginning on page 71. Always change the oil filter whenever changing oil. 1. Position the vehicle on a level surface. 2. Star t the engine. Allow it to warm up at idle for two to three minutes. 3. Stop the eng[...]

79 MAINTENANCE Engine Oil Oil and Filter Change 1 1. 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. 12. Install the new filter and rotate it clockwise by hand until the filter gasket contacts the sealing surface, then turn it an additional 1/2 turn. 13. Remove the dipstick[...]

80 MAINTENANCE T ransmission Oil Always check and change the transmission oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 71. Maintain the oil level at the bottom of the fill plug hole threads. See page 126 for the part numbers of POLARIS products. The fill plug is located on the left side of the A TV , under the r[...]

81 MAINTENANCE T ransmission Oil Oil Check 1. Position the vehicle on a level surface. 2. Remove the fill plug. Check the oil level. 3. Add the recommended fluid as needed to bring the level to the bottom of the fill hole threads. 4. Reinstall the fill plug. T orque to specification. Oil Change 1. Remove the fill plug. 2. Place a drain pan under th[...]

82 MAINTENANCE Front Gearcase (Demand Drive) Fluid Always check and change the demand drive fluid at the intervals outlined in the Periodic Maintenance Chart beginning on page 71. Maintain the fluid level at the bottom of the fill hole threads. See page 126 for the part numbers of POLARIS products. Fluid Recommendations The fill plug is located on [...]

83 MAINTENANCE Cooling System The engine coolant le vel is controlled, or main tained, by the recovery system. The recovery system components are the reco very bottle, the radiator filler neck, the radiator pressure cap and the connecting hose. As coolant operating temperature increases, the expanding (heated) excess coolant is forced out of the en[...]

84 MAINTENANCE Cooling System Radiator Coolant T o ensure that the coolant maintains its ability to protect the engine, POLARIS recommends that you drain the system completely every two years and add a fresh mixture of antifreeze and water . Replace the coolant any time the cooling system has been drained for maintenance or repair . If the recovery[...]

85 MAINTENANCE Brake Fluid Check brake fluid levels for both brake systems before each ride. Always maintain brake fluid at the r ecommended level. Do not overfill. The brakes should feel firm when they're applied. Spongy or weak brakes may indicate a fluid leak or low fluid level. A low flui d level may also mean that brake pads are worn and [...]

86 MAINTENANCE Brake Fluid Hand Brake The master cylinder is located on the left handlebar . Maintain the fluid level 6 mm below the top edge of the master cylinder . Do not over - fill. 1. Position the vehicle on a level surface. Make sure the handle- bars are straight. 2. V iew the fluid level through the indicator window (eye) on the top of the [...]

87 MAINTENANCE Brakes The front and rear brakes are hydraulic disc brakes, activated by apply- ing the foot brake. The handlebar brake is also hydraulic. Both brake systems are self-adjusting. Brake Inspections Perform the following checks to keep the brake systems in good operat- ing condition. Check more often if brakes are used heavily under nor[...]

88 MAINTENANCE T oe Alignment Use the following procedure to check the toe alignment of the vehicle. The recommended toe alignment is 1/8" to 1/4" (3-6 mm) toe out. W ARNING! Severe injury or death can result fro m improper toe alignment and adjustment. Do not attempt to adjust ti e rod alignment. All tie rod adjustments should be perform[...]

89 MAINTENANCE Power Steering Unit If your model is equipped with po wer steering, frequently clean the areas around and on the power steering unit to allow proper cooling. Clean these areas thoroughly . S teering Assembly The steering assembly of the A TV should be checked periodically for loose nuts and bolts. If loose nuts and bolts are found, s[...]

90 MAINTENANCE Side Panel Removal 1. Remove the seat. See page 89. 2. Use a flat screwdriver to remove the plastic rivets securing the side panel. 3. Grasp the rear of the side panel near the rear cab. W ith a firm motion, pull the side panel outward to disengage the side panel from the grommets. 4. Pull the panel outward and rearward to remove it.[...]

91 MAINTENANCE Footwell Removal 1. Remove the four screws on the bottom of the footwell. 2. Use a flat screwdriver to remove the plastic rivets securing the footwell to the fenders. 3. Remove the footwell. To r x H e a d Screws Plastic Rivets[...]

92 MAINTENANCE Ti r es Operating your A TV with worn tires, impr operly inflated tires, no n-standard tires or improperly installed tires will affect vehicle handling and could cause an accident resulting in serious injury or death. Alwa ys follo w all tire maintenance procedures as outlined in this manual and on the labels on the vehicle. Always u[...]

93 MAINTENANCE Ti r es Wheel Inst allation 1. Place the transmission in P ARK. 2. Place the wheel on the hub with the valve stem toward the outside and rotation arrows on the tire pointing towar d forward rotation. 3. Install the wheel nuts and finger-tighten them. 4. Lower the vehicle to the ground. 5. T orque the wheel nuts to specification. W AR[...]

94 MAINTENANCE Air Filter 1. Remove the seat. 2. Release the air box cover clips, and remove the air box cover . 3. Loosen the clamp and remove the filter . 4. Remove the fabric type pre-filter from the main filter . W ash the pre-filter in soapy water , then rinse and let dry . 5. Reinstall the pre-filter over the main filter . Install a new main [...]

95 MAINTENANCE Breather V alve/Hose The breather valve is on the hose that runs between the engine and air box. See illustration on page 94. 1. Remove the left side panel. See page 90. 2. Remove the hose clamps from the valve and pull the valve out of the hoses. 3. Inspect the valve for debris. Blow gently through the valve to check for clogging. R[...]

96 MAINTENANCE Fuse Replacement If the engine stops or will not start, or if you experience other electrical failures, a fuse may need replaceme nt. Locate and correct any short circuits that may have c aused the blown fuse, then replace the fuse. Spare fuses are provided in a compartment on the top of the access door . 1. Open the front box cover [...]

97 MAINTENANCE Light s High Beam Adjustment The headlight beam can be adjusted slightly upward or downward. Use the following procedure to make the adjustment. 1. Position the vehicle on a level surface with the headlight approximately 25 ft. (7.6 m) from a wall. Place the transmission in PA R K . 2. Measure the distance from the floor to the cente[...]

98 MAINTENANCE Light s Poor lighting can result in loss of control or an accident. Lights become dirty during normal operation. Wash the headlights and taillights frequently . Hot components can cause serious burns to skin. Do not service the headlamps until they've cooled. Headlight/Parking Light Lamp Replacement When servicing a halogen lamp[...]

99 MAINTENANCE Light s T aillight Lamp Replacement 1. Place the transmission in PA R K . 2. Rotate the taillight socket counter-clockwise to remove it. 3. Remove the lamp. 4. Apply dielectric grease to the socket. 5. Install the new lamp. T est the lamp for proper operation. 6. Reinstall all components in reverse order . Front T urn Signal Replacem[...]

100 MAINTENANCE Spar k P l u g s Sp ark Plug Recommendations Refer to the specifications section beginning on page 127 for the recommended spark plug type and gap for your vehicle. T orque spark plugs to specification. NOTICE: Using non-recommended spark plugs can result in serious engine damage. Always use POLARIS-recommended spark plugs. Sp ark P[...]

101 MAINTENANCE Spar k P l u g s Sp ark Plug Inspection Normal Sp ark Plug The normal insulator tip is gray , tan or light brown. There will be few combustion deposits. The electrodes ar e not burned or eroded. This indicates the proper type and heat range for the engine and the service. The tip should not be flaky and white. A white insulator tip [...]

102 MAINTENANCE V ehicle Immersion If your vehicle becomes immersed, major engine damage ca n result if the machine is not thoroughly inspected. T ake the vehicle to your dealer before starting the engine. If it's impossible to take your A TV to a dealer before starting it, follow the steps outlined below . 1. Move the A TV to dry land or at t[...]

103 MAINTENANCE S p ark Arrester Failure to heed the following warnings whil e servicing the spark arrester could result in serious injury or death. Never run the engine in an enclosed area. Remove any combustible materials from the area. Wear eye protectio n and leather work gloves. Do not stand behind or in fro nt of the vehicle while purging. Ne[...]

104 MAINTENANCE PVT System Failure to comply with the instructions in this warning can result in severe injury or death. Do not modify any component of the PVT system. Doing so may reduce its strength so that a failure may occu r at a high speed. The PVT system has be en precision balanced. Any modification will cause the system to be out of balanc[...]

105 MAINTENANCE PVT System The basic operation of the POLARIS PVT system is dependent on engine speed and vehicle torque requirements. As engine speed increases, the force exerted on the movable drive sheave by the flyweights also increases. This, in turn, increases the amount of pinch applied to the drive belt. Similarly , if the engine speed decr[...]

106 MAINTENANCE PVT System When to Use Low Range and High Range PVT Drying There may be some instances when water is accidently 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 drain plug. Allow the water to drain completely . Reinstall the drain p[...]

107 MAINTENANCE Battery Improperly connecting or disconnecting battery cables can result in an e xplosion and cause serious injury or death. When removing the battery , always disconnect the negative (black) cable first. When reinstalling the battery , always connect the negative (black) cable last. Battery electrolyte is poisonous. It contains sul[...]

108 MAINTENANCE Battery Battery Removal 1. Disconnect the battery hold-down strap. 2. Remove the battery cover (if equipped). 3. On conventional batteries, remove the battery vent tube. 4. Disconnect the black (negative) battery cable first. 5. Disconnect the red (positive) battery cable last. 6. Lift the battery out of the A TV . Be careful not to[...]

109 MAINTENANCE Battery Battery Inst allation Using a new battery that has not been fully char ged can damage the battery and result in a shorter life. It can also hinder vehicle performance. Follow the battery char ging instructions on page 1 1 1 before installing the battery . 1. Ensure that the battery is fully charged. 2. Place the battery in t[...]

110 MAINTENANCE Battery Battery S torage 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 char ged, and store it out of the sun in a cool, dry place. Check battery voltage each month during storage and rechar ge as needed to maintain a full char ge. Tip : Power p[...]

111 MAINTENANCE Battery Battery Charging (Conventional Battery) 1. Remove the battery from the vehicle to prevent damage from leaking or spilled electrolyte duri ng char ging. See page 108. 2. Charge the battery with a char ging output no larger than 1/10 of the battery’ s amp/hr rating. Charge as ne eded to raise the specific gravity to 1.270 or[...]

112 MAINTENANCE Battery Battery Charging (Sealed Battery) Always verify battery condition before and 1-2 hours after the end of charging. St ate of Charge V olt age Action Charge T ime (Using constant current charger @ standa rd amps specified on to p o f batt ery) 100% 12.8-13.0 volts None, che ck at 3 mos. from date of manufacture None required 7[...]

113 MAINTENANCE Camber and Caster The camber and caster are non-adjustable. Rear Spring The rear shock absorber spring is adjusted by rotating the cam either clockwise or counter-clockwise to increase or decrease spring tension. Accessory springs are available through your POLARIS dealer . Handlebars The handlebars can be adjusted for rider prefere[...]

114 MAINTENANCE Throttle Body/Idle RPM Idle RPM is preset by the manufacturer . If the engine idle speed is not satisfactory , please see your POLARIS dealer for adjustment. Throttle Cable Freeplay Adjust throttle cable freeplay at the handlebar . 1. Locate the throttle cable adjuster at the handlebar . 2. Squeeze the end of the rubber boot and sli[...]

115 MAINTENANCE Cleaning and St orage W ash ing the V ehicle Keeping your POLARIS vehicle clean will not only improve its appearance but it can also extend the life of various components. NOTICE: High water pressure may da mage component s. POLARIS recommends washing the vehicle by han d or with a garden hose, using mild soap. Certain products, inc[...]

116 MAINTENANCE Cleaning and St orage W ashing th e V ehicle If a high pressure water system is used for cleaning (not recommended), exercise extreme caution. The water may damage components and could remove paint and labels. A void directing the water stream at the following items: • Wheel bearings • Radiator • T ransmission seals •B r a k[...]

117 MAINTENANCE Cleaning and St orage Chrome Wheel Care (if equipped) Proper maintenance will protect chrome wheels from corrosion, preserve wheel life and ensure a “like new” appearance for many years. Chrome wheels exposed to road salt (or salt in the air in coastal areas) are more susceptible to corrosion if not properly cleaned. Clean chrom[...]

118 MAINTENANCE Cleaning and St orage Sto r ag e Tips NOTICE: S t arting the engine during the storage perio d will disturb the protective film created by fogging and damage could occur . Never start the engine during the storage peri od. Clean the Exterior Make any necessary repairs and clean the vehicle as recommended. See page 1 15. St abilize t[...]

119 MAINTENANCE Cleaning and St orage Sto r ag e Tips Fluid Levels Inspect the fluid levels. Add or chan ge fluids as recommended in the Periodic Maintenance Chart beginning on page 71. • Demand drive unit (front gearcase) • Rear gearcase (if equipped) • T ransmission • Brake fluid (change every two years and any time the fluid looks dark o[...]

120 MAINTENANCE Cleaning and St orage Sto r ag e Tips Inspect and Lubricate Inspect all cab les and lubricate all areas of the vehicle as recommended in the Periodic Maintenance Chart beginning on page 71. Battery Storage See pages 1 10-11 1 for storage and char ging procedures. Storage Area/Covers Set the tire pressure and safely support the A TV [...]

121 MAINTENANCE T ransporting the A TV Follow these procedures when transporting the vehicle. 1. Stop the engine. 2. Place the transmission in PA R K . 3. Secure the fuel cap, oil cap and seat. 4. Always tie the frame of the A TV to the transporting unit securely with suitable straps or rope. Do not attach tie straps to the front A-arm bolt pockets[...]

122 TROUBLESHOOTING Drive Belt Wear/Burn Possible Cause Solution Driving onto a pickup or tall trailer in high range Use low range during loading. Starting out going up a steep incl ine Use low range or turn around using the K-turn (see page 48). Driving at low RPM or ground speed Drive at a higher speed or us e low range more frequently . See page[...]

123 TROUBLESHOOTING Engine Doesn't T urn Over Engine T urns Over , Fails to St art Engine Backfires Possible Cause Solution T ripped circuit breaker or blown fuse Reset the breaker/Replace fuse Low battery voltage Recharge the battery to 12.8 VDC Loose battery connections Check all connections and tighten Loose solenoid connections Check all c[...]

124 TROUBLESHOOTING Engine Pings or Knocks Engine Runs Irregularly , St alls or Misfires Possible Cause Solution Poor quality or low octane fuel Replace with recommended fuel Incorrect ignition timing See your dealer Incorrect spark plug gap or heat range Set gap to specs or replace plugs Possible Cause Solution Fouled or defective spark plugs Insp[...]

125 TROUBLESHOOTING Engine Stop s or Loses Power Engine Overheating Possible Cause Solution Out of fuel Refuel, cycle key to ON position three times for 5 seconds each, then start Kinked or plugged fuel vent line Inspect and replace W ater is present in fuel Replace with new fuel Fouled or defective spark plugs Inspect, clean and/or replace spark p[...]

126 POLARIS PRODUCTS Part Number Description Engine Lub ricant 2870791 Fogging Oil (12 oz. Aeroso l) 2876244 PS-4 Full Syntheti c 5W-50 4-Cycle Oil (qt./.95 l) 2876245 PS-4 Full Synthetic 5W -5 0 4- Cycle Oil (gal./ 3. 8 l) 2878920 PS-4 Extreme Duty Synthetic 10W-50 4-Cycle Oil (qt./.95 l) 2878919 PS-4 Extreme Duty Synthetic 10W-50 4-Cycle Oil (gal[...]

127 SPECIFICA TIONS * Based on EU Directive 76/432/EC SPORTSMAN FOREST 570 EFI/EPS Maximum W eight Capacity 485 lbs. (220 kg) (operator, car go, accessories) Dry W eight 720 lbs. (327 kg) +/- 7%, based on configuration 731 lbs. (332 kg) (EPS) +/- 7%, based on configuration Fuel Capacity 4.5 gal. (17 l) Engine Oil Capacity 2 qts. (1.9 l) T ransmissi[...]

128 SPECIFICA TIONS Clutching Chart *EBS models require no helix/spring adjustment SPORTSMAN FOREST 570 EFI/EPS Gear Reduction, Low 23.91:1 Gear Reduction, Reverse 21.74:1 Gear Reduction, Forward 9.75:1 Drive Ratio, Front 3.82:1 T i res/Pressure, Front Off Road S tyle, Deep T read Design 25x8-12 / 5 psi (34.5 kPa) T i res/Pressure, Rear Off Road S [...]

129 W ARRANTY LIMITED W ARRANTY POLARIS Sales Inc., 2100 Highway 55, Medina, MN 55340 (POLARIS) gives a SIX MONTH LIMITED W ARRANTY on all components of your POLARIS vehicle against defects in material or workmanship. POLARIS further warrants that the spark arrestor in this product will meet the efficiency requirements of USFS standard 5100-1C for [...]

130 W ARRANTY LIMIT A TIONS OF W ARRANTIES AND REMEDIES 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 a[...]

131 W ARRANTY HOW TO OBT AIN W ARRANTY SERVICE If your vehicle requires warranty service, you must take it to a POLARIS Servicing Dealer . When requesting warranty service you must present your copy of the W arranty Registration From to the dealer . (THE COST OF TRANSPOR T A TION TO AND FROM THE DEALER IS YOUR RESPONSIBILITY). POLARIS suggests that[...]

132 W ARRANTY EXPORTED PRODUCTS EXCEPT WHERE SPECIFICALL Y REQUIRED BY LA W , THERE IS NO W ARRANTY OR SER V ICE BULLETIN COVERAGE ON THIS PRODUCT IF IT IS SOLD OUTSIDE THE COUNTR Y OF THE SELLING DEALER’S AUTHORIZED LOCA TION. This policy does not apply to products that have received authorization for export from POLARIS. Dealers may not give au[...]

133 MAINTENANCE LOG Present this section of your manual to your dealer each time your vehicle is serviced. This will provide you and future owners with an accurate log of maintenance and services performed. DA TE MILES (KM) OR HOURS TEC HNICIAN SERVICE PERFORMED / COMMENTS[...]

134 MAINTENANCE LOG DA TE MILES (KM) OR HOURS TEC HNICIAN SERVICE PERFORMED / COMMENTS[...]

135 INDEX 0-9 4X4 Switch . . . . . . . . . . . . . . . . . 22, 27 A Accessories . . . . . . . . . . . . . . . . . . . 120 Air Filte r . . . . . . . . . . . . . . . . . . . . . . 94 All Wheel Drive System . . . . . . . . . . 27 B Battery . . . . . . . . . . . . . . . . . . 107-112 Charging (Conventional) . . . . . . 111 Charging (Sealed) . . . . . .[...]

136 INDEX F Foot Brake . . . . . . . . . . . . . . . . . . . . 24 Footwell Remova l . . . . . . . . . . . . . . 91 Fuel Reco mmendations . . . . . . . . . . 26 Fuel Tank Cap . . . . . . . . . . . . . . . . . 26 Fuse Replacement . . . . . . . . . . . . . . 96 G Gauge, Code Definitions . . . . . . . 36-37 Gauge, Digital/Analog . . . . . . . . . 28-35[...]

137 INDEX R Reverse Operation. . . . . . . . . . . . . . . 54 Reverse Override Switch . . . . . . . . . 20 Rider Information Center . . . . . . 30-35 Riding Gear . . . . . . . . . . . . . . . . . . . 8-9 S Safety Label s . . . . . . . . . . . . . . . . 17-19 Safety Train ing . . . . . . . . . . . . . . . . . . 8 Safety, Winch Mainten ance . . . . .[...]

For your nearest Polaris dealer , call 1-800-POLARIS or visit www .polaris.com Polaris Sales Inc., 2100 Hwy 55 Medina, MN 55340 Phone 1-888-704-5290 Part No. 9924299 Rev 01 Printed in USA *9924299 * Before you operate this vehicle, read the owner ’ s manual[...]