POLARIS GENERAL 1000 EPS 2016 (01) PDF Document

Failure to follow the warnings contained in the manual can result in severe injury or death. Always adhere to the following safety procedures:

Operator and Passenger Requirements:

• This is an ADULT VEHICLE ONLY. You must be at least 16 years old and have a valid driver’s license to operate this vehicle.

• No person under the age of 12 may ride as a passenger. All riders must be able to sit with their backs against the seat, both feet flat on the floor, and both hands on the steering wheel (if driving) or a passenger hand hold.

• Never permit a guest to operate the vehicle unless they have read the owner’s manual and all product labels.

Protective Gear and Vehicle Use:

• Always use the cab doors while riding. Keep hands, feet, and all other body parts inside the vehicle at all times.

• The driver and all passengers must wear a helmet, eye protection, gloves, a long-sleeve shirt, long pants, and over-the-ankle boots at all times.

• Always fasten your seat belt securely before operating or riding.

Prohibited Actions:

• Never use this vehicle with drugs or alcohol, as these conditions impair judgment and reduce operator reaction time.

• This vehicle is for off-road use only. Never operate on public roads unless marked for off-road use. Always avoid paved surfaces.

• Never operate at excessive speeds. Always travel at a speed proper for the terrain, visibility, and operating conditions.

• Never attempt jumps, wheelies, or other stunts.

• Never modify the vehicle with improper non-POLARIS approved accessories, as this can create a safety hazard.

Safe Driving Practices:

• Always perform a pre-ride inspection before each use to ensure the vehicle is in safe operating condition.

• Be especially careful on hills, during turns, and when encountering obstacles to reduce rollover risk.

• Use extra caution on unfamiliar, rough, slippery, or loose terrain.

• Always follow proper procedures for turning, climbing hills, descending hills, and operating over obstacles.

• Always stop the engine before refueling. Handle gasoline with extreme caution in a well-ventilated area away from sparks or flames.

You should record your vehicle’s identification numbers and key number and keep them in a safe place. The locations are as follows:

• Frame VIN: The Vehicle Identification Number (VIN) is stamped on the vehicle’s frame. The manual shows a picture indicating it is located on a frame rail in the engine compartment area.

• Engine Serial Number: The engine serial number is located on the engine itself.

• Key Number: The key number is stamped on your key. An ignition key can only be duplicated by ordering a POLARIS key blank using your key number.

The driver and all passengers must wear protective gear at all times to reduce the chance of injury. The recommended gear includes:

• Helmet: Always wear a helmet that meets or exceeds established safety standards. Approved helmets in the USA and Canada have a Department of Transportation (DOT) label. Approved helmets in Europe, Asia, and Oceania bear an ECE 22.05 label.

• Eye Protection: Wear shatterproof goggles or a shatterproof helmet face shield. Do not depend on eyeglasses or sunglasses.

• Gloves: Wear gloves for comfort and protection.

• Boots: Wear sturdy over-the-ankle boots for support and protection.

• Clothing: Wear a long-sleeve shirt and long pants to protect arms and legs.

The gear selector (shifter) on your POLARIS GENERAL 1000 EPS 2016 has the following positions:

• H: High Gear

• L: Low Gear

• N: Neutral

• R: Reverse

• P: Park

To shift gears, bring the vehicle to a complete stop, apply the brake, and move the lever to the desired gear while the engine is idling. Shifting gears while the vehicle is moving or the engine speed is above idle could cause transmission damage.

Using Low Range (L)

Low gear is the primary driving range. Always shift into low gear for any of the following conditions to prevent drive belt burning and ensure proper performance:

• Operating in rough terrain or over obstacles

• Loading the vehicle onto a trailer

• Towing loads

• Driving frequently at low RPM or at ground speeds below 7 MPH (11 km/h)

The switches on your POLARIS GENERAL 1000 EPS 2016 console function as follows:

Ignition Switch (Key-operated)

• OFF: The engine is off. Electrical circuits are off, except for the 12V accessory power.

• ON: Electrical circuits are on. Electrical equipment can be used.

• START: Turn the key to this position to engage the electric starter. The key returns to the ON position when released.

Winch Switch

• Press the top of the rocker switch (OUT) to spool the line out from the winch.

• Press the bottom of the rocker switch (IN) to spool the line in to the winch.

• The center position stops the winch.

All Wheel Drive (AWD) Switch

• AWD position: Engages All Wheel Drive.

• 2WD position: Engages Two Wheel Drive.

Light Switch

• The ignition key must be in the ON position.

• Press the top of the switch (HIGH) for high beam headlights.

• Move the switch to the center (LOW) for low beam headlights.

• Press the bottom of the switch (OFF) to turn off the headlights.

Adjustable Steering Wheel

The steering wheel can be tilted for rider preference. To adjust it:

1. Lift and hold the adjustment lever located under the steering column.

2. Move the steering wheel upward or downward to the desired position.

3. Release the adjustment lever to lock the steering wheel in place.

Brake Pedal

Depress the brake pedal to slow or stop the vehicle. Always apply the brakes when starting the engine.

Throttle Pedal

Push the throttle pedal down to increase engine speed. Spring pressure will return the pedal to the rest position when released. Always check that the throttle pedal returns normally before starting the engine. If the throttle and brake pedals are applied at the same time, engine power may be limited.

The electrical compartment, which contains the battery and fuse box, is located under the driver’s seat. To access this area:

1. Pull the rear edge of the driver’s seat upward. This will release the latch pins from the grommets.

2. Roll the seat forward to access the under-seat area.

3. To completely remove the seat, roll it forward and lift the seat tabs from the seat base mounts.

Important: Always make sure the seat is properly reinstalled and securely latched before operating the vehicle. Push down firmly on the rear of the seat until the latch pins are fully seated in the grommets.

To remove the hood and access the cooling system components, follow these steps:

1. Turn the two hood fasteners 1/4 turn.

2. Grasp the upper edge of the hood and pull upward to disengage the fasteners.

3. Pivot the hood forward and then lift it upward to disengage the lower hood hooks.

4. Lift the hood away from the vehicle.

CAUTION: Escaping steam can cause burns. Never remove the radiator pressure cap while the engine is warm or hot. Always allow the engine to cool completely before removing the cap.

Proper use and inspection of seat belts are critical for safety. The driver’s seat belt has an interlock that will limit vehicle speed to 15 MPH (24 km/h) if not secured.

How to Wear the Seat Belt:

1. Pull the seat belt latch downward and across your chest toward the buckle located at the inner edge of the seat. The belt should fit snugly across your hips and diagonally across your chest. Ensure the belt is not twisted.

2. Push the latch plate into the buckle until it clicks.

3. Release the strap; it will self-tighten.

4. To release the seat belt, press the square red button in the center of the buckle.

Seat Belt Inspection (Before Each Use):

1. Push the latch plate into the buckle until it clicks to ensure it latches smoothly and securely.

2. Push the red release button to make sure it releases freely.

3. Pull each seat belt completely out and inspect the full length for any damage, such as cuts, wear, fraying, or stiffness. If damage is found or the belt does not operate properly, have it checked by an authorized dealer.

4. To clean the seat belts, sponge the straps with mild soap and water. Do not use bleach, dye, or household detergents.

The Rider Information Center has three main display areas and is controlled by the MODE button and toggle buttons.

Display Areas and Modes:

• Area 1 Modes (Cycle with MODE button): Engine Temperature, Vehicle Speed, Tachometer (RPM).

• Area 2 Modes (Cycle with toggle buttons): Odometer, Trip Meters (T1/T2), Engine Hours, Service Hours, Trip Time.

• Area 3 Modes: Clock (12-hour or 24-hour format).

Accessing Menus and Options:

1. Press and hold the MODE button to enter the settings menu. The screen will display “OPTIONS”.

2. Press and release a toggle button to cycle to the desired option (e.g., BL COLOR, CLOCK, UNITS, Service Hours).

3. Press MODE to select that option.

4. Use the toggle buttons to change the setting.

5. Press MODE to save the setting and exit to the settings menu.

6. Press and hold the MODE button to exit the settings menu completely.

Resetting Trip Meters/Time:

• Cycle to the desired trip meter (T1, T2) or trip time (TT) using the toggle buttons.

• Press and hold a toggle button until the value resets to zero.

Viewing Engine Error Codes:

If the CHECK ENGINE light is on, you can retrieve the code:

1. Press and hold the MODE button to enter the settings menu.

2. Use a toggle button to cycle to “DIAGCODE” and press MODE to select.

3. If multiple codes exist, use the UP toggle button to view them. Press MODE to select a code.

4. Record the three numbers displayed (Suspect Parameter Number, Failure Mode Indicator, and Code Count).

5. Press MODE to exit.

The break-in period for your new POLARIS GENERAL 1000 EPS 2016 is the first 25 hours of operation or the first two tanks of fuel. Proper break-in will ensure a longer life and better performance. During this period, do not operate at full throttle or high speeds for extended periods.

Engine and Drivetrain Break-in:

1. Fill the fuel tank with clean, fresh fuel.

2. Check the oil level and add oil if needed.

3. Drive slowly at first to familiarize yourself with the vehicle.

4. Vary throttle positions. Do not operate at a sustained idle.

5. Perform regular checks on fluid levels, controls, and other areas on the pre-ride inspection checklist.

6. Change the oil and filter at 25 hours.

7. Check fluid levels in the transmission and all gearcases after the first 25 hours.

8. Pull only light loads.

PVT (Clutches/Belt) Break-in:

• Operate at slower speeds during the break-in period.

• Pull only light loads.

• Avoid aggressive acceleration and high-speed operation.

Always inspect your vehicle before each use to ensure it is in safe operating condition. Failure to do so increases the risk of an accident.

Starting the Engine

1. Always start the engine outdoors or in a well-ventilated area.

2. Sit in the driver’s seat, fasten the seat belt, and ensure all cab doors are closed and latched.

3. Place the transmission in PARK.

4. Apply the brakes. Do not press the throttle pedal.

5. Turn the ignition key past the ON position to START. Engage the starter for a maximum of five seconds. Release the key when the engine starts.

6. If the engine doesn’t start, release the key, wait five seconds, and repeat the process.

Stopping the Engine

1. Release the throttle pedal completely and use the brake to bring the vehicle to a complete stop.

2. Place the transmission in PARK.

3. Turn the engine off.

4. Slowly release the brake pedal, making sure the vehicle is securely in PARK before exiting.

Driving Over Obstacles:

• Always check for obstacles before operating in a new area.

• Travel slowly and use extra caution. Avoid large obstacles like rocks and fallen trees.

• If an obstacle could cause a rollover, have passengers dismount and move away.

Driving on Slippery Surfaces (Ice, Gravel):

• Slow down and maintain a high level of alertness.

• Engage All-Wheel Drive (AWD) before you lose traction.

• Avoid quick, sharp turns. To correct a skid, turn the steering wheel in the direction of the skid. Never apply brakes during a skid.

Driving Uphill:

• Always travel straight uphill. Avoid excessively steep hills.

• Proceed at a steady rate of speed. Never apply throttle suddenly.

• Never go over the crest of a hill at high speed.

Driving Downhill:

• Always check the terrain before descending.

• Slow down. Travel straight down the hill where possible.

• Always descend with the transmission in a forward gear, never in neutral. Apply the brakes lightly to aid in slowing.

Driving Through Water:

• Do not operate in water deeper than the floorboards.

• Determine water depth and current before entering. Choose a crossing with gradual inclines.

• Proceed slowly, avoiding rocks and obstacles. Avoid deep or fast-flowing water.

• After leaving water, test your brakes and apply them lightly several times to dry the pads.

Hauling Cargo

• Never exceed the maximum weight capacity of the vehicle (1030 lbs / 467 kg), which includes the operator, passenger, accessories, and cargo.

• The maximum cargo box load is 600 lbs (272 kg).

• Always load cargo as far forward and as low as possible in the cargo box.

• Secure all loads before operating.

• Reduce speed and allow for greater braking distances when hauling cargo.

• Never allow passengers to ride in the cargo box.

Dumping the Cargo Box

1. Park on a level site and place the transmission in PARK.

2. Ensure cargo is positioned evenly or toward the front of the box.

3. Stand clear and pull one of the cargo box release levers upward to lift the front of the box and dump the cargo.

4. Lower the box and push down securely to latch. Never operate the vehicle with the cargo box raised.

Towing Loads

Towing improperly can alter vehicle handling. Follow these precautions:

• Always operate in low gear when towing.

• Avoid towing on an incline. If unavoidable, drive straight up or down the incline with extreme caution.

• Attach the trailer only to the trailer hitch bracket.

Improper winch use can result in severe injury or death. Always follow these procedures:

Safety First:

• Inspect the winch, cable, and controls for damage before each use.

• Wear eye protection and heavy gloves.

• Keep the area clear of people, especially children.

• Apply the vehicle’s park brake to hold it in place.

Winching Procedure:

1. Use the hook strap to handle the hook. Never put your fingers in the hook.

2. Release the winch clutch and pull out the necessary length of winch cable. Always leave at least five full turns of cable on the winch drum.

3. Secure the hook to the load using a tow strap or chain. Never hook the winch cable back onto itself. Ensure the safety latch on the hook is fully seated.

4. Place a “damper” (heavy jacket, tarp, or other soft object) over the midpoint of the winch cable to absorb energy in case of cable failure.

5. Re-engage the winch clutch.

6. Slowly winch in the slack in the cable.

7. Operate the winch using the IN/OUT switch on the dash. Winch slowly and deliberately. If the winch motor becomes hot (after 45 seconds of use or if it stalls), stop and let it cool for 10 minutes.

8. After winching, you may need to re-spool the cable. Have an assistant pull the cable with about 100 lbs. of tension while you slowly winch it in, moving the cable back and forth to distribute it evenly on the drum.

Never:

• “Jerk” a load with the winch.

• Use the winch for lifting or transporting people.

• Tow another vehicle with the winch.

Checking the Engine Oil (when engine is cold)

1. Park the vehicle on a level surface and place the transmission in PARK.

2. Lift the cargo box to access the engine components.

3. Remove the dipstick, wipe it dry with a clean cloth, and reinstall it completely.

4. Remove the dipstick again and check the oil level. It should be between the minimum and maximum marks.

5. If low, remove the oil fill cap and add the recommended oil (POLARIS PS-4 5W-50 4-Cycle Oil or similar) as needed. Do not overfill.

6. Reinstall the fill cap and dipstick. Lower the cargo box securely.

Changing the Engine Oil and Filter

1. Perform steps 1-2 from the check procedure.

2. Place a drain pan under the engine crankcase. The drain plug is accessible through a hole in the skid plate.

3. Clean the area around the drain plug, then remove the plug and allow the oil to drain completely.

4. Using an oil filter wrench, remove the old oil filter.

5. Clean the filter sealing surface on the crankcase.

6. Apply a film of fresh oil to the O-ring on the new filter.

7. Install the new filter and turn by hand until the gasket contacts the sealing surface, then turn an additional 1/2 turn.

8. Reinstall the drain plug and torque to 12 ft-lbs (16 Nm).

9. Add 2.5 quarts (2.4 L) of recommended oil.

10. Start the engine and check for leaks. Stop the engine, wait 15 seconds, and re-check the oil level, adding oil as needed to reach the upper mark on the dipstick.

11. Dispose of used oil and filter properly.

Always check and change gearcase fluids at the intervals outlined in the Periodic Maintenance Chart. Park the vehicle on a level surface before checking or changing fluids.

Gearcase Fluid Specifications:

Transmission (Main Gearcase) Maintenance:

• Check Level: The check/fill plug is on the rear of the gearcase. Remove the plug; the fluid level should be even with the bottom of the plug hole threads. Add fluid as needed.

• Change Fluid: The drain plug is near the bottom of the gearcase. Remove the fill plug, then the drain plug. Allow the oil to drain completely. Reinstall the drain plug, add the correct amount of new fluid, and reinstall the fill plug.

Front Gearcase Maintenance:

• Check Level: The fill plug is on the right side of the gearcase. Remove the plug; the fluid level should be even with the bottom of the plug hole threads. Add fluid as needed.

• Change Fluid: Remove the fill plug. Place a drain pan under the drain plug and remove it. Allow the fluid to drain completely. Reinstall the drain plug, add the correct amount of new fluid, and reinstall the fill plug.

Overflow Bottle Coolant Level Check

1. Park the vehicle on a level surface.

2. Remove the hood.

3. View the coolant level in the overflow bottle. When the fluid is cool, the level should be between the minimum and maximum marks.

4. If the level is low, add POLARIS Antifreeze 50/50 Premix to the overflow bottle. Do not add coolant through the radiator cap opening unless the overflow bottle is empty.

Radiator Coolant Level Check

Check the radiator level ONLY if the overflow bottle is completely dry.

1. Allow the engine to cool completely.

2. Remove the hood.

3. Slowly remove the radiator pressure cap.

4. View the coolant level through the opening and slowly add coolant as needed.

5. Reinstall the pressure cap securely.

6. Add coolant to the overflow bottle to the recommended level.

Radiator and Cooling Fan Maintenance

• Periodically check and clean the radiator fins and screen of any debris.

• Do not install accessories that obstruct airflow to the radiator.

• Avoid using a high-pressure hose to clean the radiator fins, as this can damage them.

If your vehicle becomes immersed, major engine damage can result if it is not thoroughly inspected before starting. Taking it to a dealer is recommended. If that is not possible, follow these steps immediately:

1. Move the vehicle to dry land or at least to water below the floorboard level.

2. Dry any water present in the air box. If water is present, the air filter must be replaced.

3. Dry any water present in the intake manifold.

4. Remove the spark plugs. Turn the engine over several times using the electric start to clear water from the cylinders.

5. Dry the spark plugs and reinstall them, or replace them with new plugs.

6. Attempt to start the engine. If it doesn’t start, repeat the drying procedure.

7. Whether you succeed in starting it or not, take the vehicle for service as soon as possible.

8. If water has entered the PVT (clutch) system, follow the PVT Drying procedure.

Proper headlight adjustment is crucial for visibility. If a headlight is damaged, the entire assembly must be replaced.

Headlight Beam Adjustment Procedure:

1. Place the vehicle on a level surface with the headlights approximately 25 ft. (7.6 m) from a wall.

2. Place the transmission in PARK.

3. Measure the distance from the floor to the center of the headlight and make a mark on the wall at the same height.

4. Apply the brakes, start the engine, and turn on the headlights.

5. Observe the headlight beam on the wall. The most intense part of the beam should be aimed 8 inches (20 cm) below the mark you placed on the wall. It’s recommended to have a rider’s weight in the seat during this step.

6. If adjustment is needed, locate the adjustment screw on the side of the headlight.

7. Loosen the screw, adjust the headlight to the correct aim, and then tighten the screw.

8. Repeat the check and adjustment process until the lamp is properly aimed.

Your vehicle has a sealed battery that requires little maintenance but must be kept clean and fully charged.

Battery Removal

1. Remove the driver’s seat to access the battery.

2. Important: Disconnect the black (-) negative battery cable first.

3. Disconnect the red (+) positive battery cable last.

4. Remove the battery hold-down strap and lift the battery out.

Battery Installation

1. Ensure the new or stored battery is fully charged (12.8 V or higher).

2. Place the battery in the holder with the positive terminal toward the driver’s side.

3. Coat the terminals with dielectric grease.

4. Important: Connect and tighten the red (+) positive cable first.

5. Connect and tighten the black (-) negative cable last.

6. Install the hold-down strap and reinstall the seat.

Battery Charging and Storage

• The single most important thing for a sealed battery is to keep it fully charged. Use a voltmeter to check the DC voltage.

• For a refresh charge, if the voltage is below 12.8 volts, charge at 1.2 amps or less until the voltage is 12.8 or greater.

• When storing the vehicle for three months or more, remove the battery, ensure it’s fully charged, and store it in a cool, dry place. Check the voltage monthly and recharge as needed.

Proper storage preperation will prevent damage and ensure your vehicle is ready for its next use.

1. Clean the Vehicle: Wash and polish the vehicle as recommended.

2. Stabilize the Fuel: Fill the fuel tank and add POLARIS Carbon Clean Fuel Treatment or a similar fuel stabilizer. Run the engine for 15-20 minutes to allow the stabilizer to circulate through the entire fuel system.

3. Change Oil and Filter: Change the engine oil and filter.

4. Service Air Filter: Replace the air filter and clean the air box.

5. Fog the Engine: To prevent corrosion, remove the spark plugs and add 2-3 tablespoons of engine oil into each spark plug hole. Turn the engine over several times to coat the cylinder walls. Reinstall the spark plugs and apply dielectric grease to the caps.

6. Inspect and Lubricate: Lubricate all areas of the vehicle as recommended in the periodic maintenance chart.

7. Battery Maintenance: Remove the battery, ensure it’s fully charged, and store it in a cool, dry place. Check and recharge it monthly.

8. Check Fluid Levels: Inspect all fluid levels and add or change as needed.

9. Storage Area: Store the vehicle in a well-ventilated area. Cover it with a genuine POLARIS cover, not plastic, to prevent condensation and corrosion.

Follow these procedures when transporting the vehicle:

1. Place the transmission in PARK.

2. Stop the engine and ensure the vehicle is securely in PARK.

3. Secure the fuel cap, hood, doors (if equipped), and cargo box. Ensure seats are correctly attached and not loose.

4. Secure or remove all loose cargo to prevent it from flying off during transport.

5. Always tie the frame of the POLARIS vehicle securely to the transporting unit (trailer or flatbed) with suitable straps or rope. Do not attach tie straps to the front A-arm bolt pockets.

6. Remove the ignition key to prevent loss during transport.

Engine Doesn’t Turn Over

• Low battery voltage: Recharge the battery to 12.8 VDC.

• Loose battery/solenoid connections: Check all connections and tighten.

Engine Turns Over, Fails to Start

• Out of fuel: Refuel.

• Water in fuel: Drain the fuel system and refuel with fresh fuel.

• Fouled or defective spark plugs: Inspect plugs and replace if necessary.

• Low battery voltage: Recharge the battery to 12.8 VDC.

Engine Backfires

• Weak spark from spark plug: Inspect, clean, and/or replace spark plugs.

• Incorrect spark plug gap or heat range: Set gap to specs or replace plugs.

• Old or non-recommended fuel: Replace with fresh recommended fuel.

Engine Stops or Loses Power

• Out of fuel: Refuel.

• Clogged air filter: Inspect and clean or replace.

• Incorrect spark plug gap or heat range: Set gap to specs or replace plug.

• Overheated engine: Clean radiator screen and core, and clean the engine exterior.