Polaris PRO XD User manual

OWNER’S
MANUAL
For Maintenance and Safety
PRO XD
2022

WARNING
Operating, servicing, and maintaining a passenger vehicle or off-road
vehicle can expose you to chemicals including engine exhaust, carbon
monoxide, phthalates, and lead, which are known to the State of California
to cause cancer and birth defects or other reproductive harm. To minimize
exposure, avoid breathing exhaust, do not idle the engine except as
necessary, service your vehicle in a well-ventilated area and wear gloves
or wash your hands frequently when servicing your vehicle.
For more information go to www.P65Warnings.ca.gov/passenger-vehicle.
!WARNING
Read, understand, and follow all of the instructions and safety
precautions in this manual and on all product labels.
Failure to follow the safety precautions
could result in serious injury or death.
For videos and more information
about a safe riding experience with
your Polaris vehicle, scan this QR
Code®with your smartphone.
!

2022 Owner’s Manual
Pro XD Full-Size

Unless noted, trademarks are the property of Polaris, Inc.
Loctite® is a registered trademark of Henkel Corporation. NYOGEL® is a
registered trademark of Nye Lubricants, Inc. Tread Lightly® is a registered
trademark of the United States Department of Agriculture. QR Code® is a
registered trademark of DENSO WAVE INCORPORATED. WD-40® is
registered to WD-40 Manufacturing Company. Bluetooth® is a registered
trademark of Bluetooth Sig, Inc.
Copyright 2021 Polaris, 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 result between the actual vehicle and the
information presented in this publication. Depictions and/or procedures in this
publication are intended for reference use only. No liability can be accepted
for omissions or inaccuracies. Any reprinting or reuse of the depictions and/or
procedures contained within, whether whole or in part, is expressly
prohibited.
The original instructions for this vehicle are in English. Other languages are
provided as translations of the original instructions.
Printed in U.S.A.
9940401 R02

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. We believe POLARIS sets a standard of excellence for all utility and
recreational vehicles manufactured in the world today. Many years of experience
have gone into the engineering, design, and development of your POLARIS
vehicle.
For safe and enjoyable operation of your vehicle, be sure to follow the
instructions and recommendations in this owner’s manual. Your manual contains
instructions for minor maintenance, but information about major repairs is
outlined in the POLARIS Service Manual and can be performed by a factory
certified Master Service Dealer (MSD) technician.
Your POLARIS dealer knows your vehicle best and is interested in your total
satisfaction. Your POLARIS dealership can perform all of your service needs
during and after the warranty period.
For the most up-to-date owner’s manual visit https://www. polaris.
com/en-us/owners-manuals.
3
WELCOME

4
WELCOME

Introduction . . . . . . . . . . . . . . . . . . . . 7
Safety . . . . . . . . . . . . . . . . . . . . . . 11
Features and Controls . . . . . . . . . . . . . . 31
Operation . . . . . . . . . . . . . . . . . . . . 65
Winch Guide. . . . . . . . . . . . . . . . . . . 85
Emission Control Systems . . . . . . . . . . . . . 95
Maintenance . . . . . . . . . . . . . . . . . . 97
Specifications . . . . . . . . . . . . . . . . . . 151
POLARIS Products . . . . . . . . . . . . . . . . 157
Troubleshooting . . . . . . . . . . . . . . . . . 159
Warranty . . . . . . . . . . . . . . . . . . . . 163
Maintenance Log . . . . . . . . . . . . . . . . 173
5

6

INTRODUCTION
IMPORTANT INFORMATION
WARNING
Failure to follow the warnings contained in this manual can result in severe
injury or death.
This vehicle is not a toy and can be hazardous to operate. This vehicle handles
differently than other vehicles. A collision or rollover can occur quickly, even
during routine maneuvers, if you fail to take proper precautions.
• Read this owner’s manual. Understand all safety warnings, precautions and
operating procedures before operating the vehicle. Keep this manual with
the vehicle at all times.
• This vehicle is an ADULT VEHICLE ONLY. You MUST be at least 16 years
of age and have a valid driver’s license to operate this vehicle.
• No person under the age of 12 may ride as a passenger in this vehicle.
• Never permit a guest to operate this vehicle unless the guest has read this
manual and all product labels.
• Always keep hands, feet, and all other body parts inside the vehicle at all
times.
• Always wear the proper clothing when operating or riding in this vehicle. All
riders should wear substantial footwear, long pants, and a close-fitting shirt.
A hard hat or helmet and approved eye protection are recommended when
appropriate for riding or working conditions.
• Never operate this vehicle under the influence of drugs or alcohol, as these
conditions impair judgement and the operator’s ability to react.
7
INTRODUCTION

SAFETY SYMBOLS AND SIGNAL WORDS
The following signal words and symbols appear throughout this manual and on
your vehicle. Your safety is involved when these words and symbols are used.
Become familiar with their meanings before reading the manual.
DANGER
DANGER indicates a hazardous situation which, if not avoided, WILL result in
death or serious injury.
WARNING
WARNING indicates a hazardous situation which, if not avoided, COULD result
in death or serious injury.
CAUTION
CAUTION indicates a hazardous situation which, if not avoided, COULD result
in minor to moderate injury.
NOTICE
NOTICE provides key information by clarifying instructions.
IMPORTANT
IMPORTANT provides key reminders during disassembly, assembly, and
inspection of components.
The Prohibition Safety Sign indicates an action NOT to take in
order to avoid a hazard.
The Mandatory Action Sign indicates an action that NEEDS to
be taken to avoid a hazard.
8
INTRODUCTION

VEHICLE IDENTIFICATION NUMBERS
Record your vehicle's identification numbers in the spaces provided. The engine
serial number is located on the side of the engine, below the injection pump.
All keys have the number 4083. Remove the spare key and store it in a safe
place. Additional pre-cut keys for your vehicle can be ordered.
The engine serial number can be found
on a decal applied to the front of the
engine crankcase q
or stamped into
the crankcase on the PTO side of the
engine w.
The VIN can be found stamped on a
portion of the left rear frame q, above
the PVT cover.
Vehicle Model Number
Vehicle Identification Number (VIN)
q
Engine Serial Number w
Key Number 4083
9
INTRODUCTION

10

SAFETY
PERSONAL PROTECTIVE EQUIPMENT
Always wear the proper clothing when operating or riding in this vehicle. All
riders should wear substantial footwear, long pants and a close-fitting shirt. A
hard hat or helmet and approved eye protection are recommended when
appropriate for working or riding conditions. POLARIS recommends wearing
approved eye protection bearing markings such as VESC 8, V-8, Z87.1 or CE.
Never operate or ride in this vehicle while barefoot or while wearing sandals or
tennis shoes.
Workplace safety regulations may require the use of safety glasses, safety
shoes and a hard hat or helmet. Familiarize yourself with local requirements, be
prepared for operating conditions and wear the appropriate safety gear.
Department of Transportation (DOT) approved
helmets are required for all riders when operating at 30
MPH or above. Approved helmets in the USA and
Canada bear a U.S. Department of Transportation
label.
RIDER COMFORT
Under certain operating conditions, heat generated by the engine and exhaust
system can elevate temperatures in the driver and passenger cab area. The
condition occurs most frequently when a vehicle is being operated in high
ambient temperatures at low speeds and/or high load conditions for an extended
period of time. The use of certain windshield, roof and/or cab systems may
contribute to this condition by restricting airflow. Any discomfort due to heat
buildup in this area can be minimized by wearing proper riding apparel and by
varying speeds to increase airflow.
11
SAFETY

SAFETY LABELS AND LOCATIONS
Warning labels have been placed on the vehicle for your protection. Read and
follow the instructions of the labels on the vehicle carefully. If any of the labels
depicted in this manual differ from the labels on your vehicle, always read and
follow the instructions of the labels on the vehicle.
If an informational or graphic label becomes illegible or comes off, contact your
POLARIS dealer to purchase a replacement. Replacement safety labels are
provided by POLARIS at no charge. The part number is printed on the label.
The seat belt/drive responsibly warning label , the proper use warning label, and
the payload warning are located on the front ROPS, above the driver’s head q.
SEAT BELT / DRIVE RESPONSIBLY WARNING
WARNING
Part Number: 7300410
IMPROPER VEHICLE USE CAN RESULT IN SERIOUS INJURY OR DEATH
NEVER OPERATE:
• At speeds too fast for your skills or the conditions.
• After or while using Alcohol or Drugs.
• Across slopes (Avoid side hilling).
• On public roads. This vehicle is for off-highway use only. Driving on public
roads could be a violation of law and may be hazardous.
12
SAFETY

• With more passengers than described in the Operation & Maintenance
Manual, with children under the age of 12, and passengers who cannot
comfortably reach the floor and hand holds with back against the seat.
• With unapproved accessories - they may seriously affect stability.
LOCATE AND READ OPERATION & MAINTENANCE MANUAL. FOLLOW
ALL INSTRUCTIONS AND WARNINGS.
ALWAYS:
• Wear head protection - such as a hard hat or helmet - as appropriate for
conditions and usage. Consult manual for more information.
• Wear your seatbelt. Vehicle rollover could cause serious injury or death.
• Wear eye protection and keep hands and feet in vehicle at all times.
• Reduce speed and use extra caution when carrying passengers.
• Avoid sharp turns or turns while applying heavy throttle.
• Operate slowly in reverse - avoid sharp turns or sudden braking.
• Make sure passengers read and understand all warning labels.
• Watch for branches or other hazards that could enter vehicle.
• Use caution while operating vehicle on private paved surfaces. Pavement can
alter handling and may cause loss of control.
Be Sure Riders Pay Attention and Plan Ahead
If you think or feel the vehicle may tip or roll, reduce your risk to injury:
• Keep a firm grip on the steering wheel or handholds and brace yourself.
• Do not put any part of your body outside of the vehicle for any reason.
Rollovers have caused severe injuries and death, even on flat, open areas.
13
SAFETY

PROPER USE WARNING (2-SEAT)
WARNING
Part Number: 7300098
Require Proper Use of Your Vehicle
Do your part to prevent injuries:
• Do not allow careless or reckless driving.
• Make sure operators are 16 or older with a valid driver’s license.
• Do not let people drive or ride after using alcohol or drugs.
• Do not allow operation on public roads (unless designated for off-highway
vehicle access) - collisions with cars and trucks can occur.
• Do not exceed seating capacity: 2 occupants.
PROPER USE WARNING (4-SEAT)
WARNING
Part Number: 7300099
Require Proper Use of Your Vehicle
Do your part to prevent injuries:
• Do not allow careless or reckless driving.
• Make sure operators are 16 or older with a valid driver’s license.
• Do not let people drive or ride after using alcohol or drugs.
• Do not allow operation on public roads (unless designated for off-highway
vehicle access) - collisions with cars and trucks can occur.
• Do not exceed seating capacity: 4 occupants.
14
SAFETY

PAYLOAD WARNING
WARNING
Part Number: 7300640
WARNING
MODEL NEVER EXCEED IF TOTAL PAYLOAD
EXCEEDS
Full-Size Diesel 25 mph (40 kph) 860 lbs. (376 kg)
Full-Size Diesel Crew 25 mph (40 kph) 860 lbs. (376 kg)
Full-Size Gas 25 mph (40 kph) 1250 lbs. (567 kg)
Full-Size Gas Crew 25 mph (40 kph) 1250 lbs. (567 kg)
FUEL TRANSPORT WARNING
The fuel transport warning label q is located in the cargo box.
WARNING
Part Number: 7186122
NEVER carry fuel or other flammable liquids on this vehicle.
Failure to follow this instruction could lead to serious burn injuries or death.
15
SAFETY

LOAD/PASSENGER/TIRE PRESSURE WARNING
The load/passenger/tire pressure warning label is located next to the fuel
transport warning label in the cargo box.
WARNING
Part Number: 7300637
WARNING
FALLING OFF CARGO BOX CAN CAUSE SERIOUS INJURY OR DEATH
• Never carry riders in cargo box.
OVERLOADING OR IMPROPER TIRE PRESSURE CAN CAUSE TIPPING
OR LOSS OF CONTROL RESULTING IN SERIOUS INJURY OR DEATH
• Never exceed load capacities.
• Reduce speed and allow greater distance for braking when carrying cargo.
• Carrying tall, off-center, or unsecured loads will increase your risk of losing
control. Center and secure loads as low as possible in box.
• Reduce speed and cargo on rough or hilly terrain.
• Check for proper tire pressures.
MODEL
NUMBER
FULL-SIZE
DIESEL
FULL-SIZE
DIESEL
CREW
FULL-SIZE
GAS
FULL-SIZE
GAS CREW
MAXIMUM
CARGO BOX
LOAD
1250 lbs.
(566 kg)
1250 lbs.
(566 kg)
1250 lbs.
(566 kg)
1250 lbs.
(566 kg)
TIRE
PRESSURE
IN PSI (KPa)
FRONT 24
(165)
REAR 24
(165)
FRONT 24
(165)
REAR 24
(165)
FRONT 5 (34)
REAR 20
(138)
FRONT 10
(69)
REAR 20
(138)
VEHICLE
RATED
CAPACITY
INCLUDES
WEIGHT OF
OPERATOR,
PASSENGER,
CARGO, AND
ACCESSO-
RIES.
1900 lbs.
(861 kg)
2075 lbs.
(941 kg)
1900 lbs.
(861 kg)
2075 lbs.
(941 kg)
16
SAFETY

MODEL
NUMBER
FULL-SIZE
DIESEL
FULL-SIZE
DIESEL
CREW
FULL-SIZE
GAS
FULL-SIZE
GAS CREW
GVWR 3600 lbs.
1632 kg
4000 lbs.
1814 kg
3600 lbs.
1632 kg
4000 lbs.
1814 kg
Read Operation & Maintenance Manual for more detailed loading information.
CLUTCH COVER WARNING
The clutch cover warning q is located on the clutch cover.
WARNING
Part Number: 7182350
Improper service or maintenance of this CVT system can result in vehicle
damage, SEVERE INJURY or DEATH.
Always look for and remove debris inside and around clutch and vent system
when replacing belt.
Read owner’s manual or see an authorized service dealer.
17
SAFETY

SHIFT CAUTION
The shift caution q is located above the ignition switch.
CAUTION
Part Number: 7300087
To avoid transmission damage, shift only when vehicle is stationary and at idle.
When vehicle is stopped, place gear selector in PARK.
TRAILER/HITCH CAPACITY
The trailer/hitch capacity label is located on the rear hitch bracket.
CAUTION
Part Number: 7300095
CAUTION:
HOT SURFACE. DO NOT TOUCH.
TRAILER MAX. WEIGHT: 2500 LBS. (1134 kg)
HITCH MAX. VERTICAL WEIGHT: 250 LBS. (114 kg)
18
SAFETY