P5500 (2020) - Electric generator POLARIS - Free user manual and instructions

Product Type	Portable electric generator
Brand	Polaris
Model	P5500 (2020)
Maximum Power	5 500 W
Rated Power	5 000 W
AC Output Voltage	120 V / 240 V
AC Outlets	4 x 120 V outlets + 1 locking 120/240 V outlet
DC Outlet	1 x 12 V outlet for battery charging
Engine Type	4-stroke gasoline, single-cylinder
Recommended Fuel	Unleaded gasoline, 87 octane minimum
Engine Oil Capacity	1 100,1 mL (5W-30)
Starting System	Electric (key) and recoil starter
Noise Level	70 dB(A) at 7 m
Circuit Protection	AC and DC circuit breakers, overload breaker
Ground Terminal	Yes, for grounding
Warranty	2 years on emissions control system
Included Accessories	Oil funnel, tool kit (spark plug wrench, battery cable)
Max. Altitude	Up to 915 m without carburetor modification
Periodic Maintenance	Oil change every 50 h, air filter cleaned every 50 h
Intended Use	Backup power, construction sites, camping

Frequently Asked Questions - P5500 (2020) POLARIS

Can I use my Polaris P5500 generator indoors?

No, never indoors. Exhaust contains toxic, odorless carbon monoxide (CO). Use it only outdoors, away from windows, doors, and air vents.

What type of engine oil to use?

Use Polaris 5W-30 oil for 4-stroke engines. Capacity is 1 100,1 mL. Check level at every use.

What if the generator does not start?

Check oil level, fuel, and fuel valve position. Make sure the choke is closed for cold start. Use the recoil starter if the battery is weak.

How to connect a 240 V device?

Use the twist-lock outlet (120/240 V). Do not exceed the rated power of 5 000 W (max 5 500 W for 30 minutes). See the power table in the manual.

Can I recharge my car battery with this generator?

Yes, use the 12 V DC outlet with the supplied cable. The DC output voltage is unregulated; it is only for charging 12 V batteries. Do not connect a DC motor.

What is the emergency shutdown procedure?

Turn the ignition key to OFF. Then close the fuel valve. In case of immediate danger, turn off the key first.

How often should I change the oil?

Change oil after the first 20 hours, then every 3 months or 50 hours per the maintenance table. Use recommended Polaris 5W-30 oil.

How to clean the air filter?

Every 50 hours, remove the filter, clean with soapy water, rinse and let dry. Reinstall after saturating with engine oil. Replace if damaged.

What does the red light on the panel mean?

The indicator light is green when the engine runs normally. If it flashes or is red, it indicates a fault (overload, error). See the troubleshooting section.

How to transport the generator safely?

Drain the fuel tank before transport. Lock the wheels and use the lifting bracket if available. Secure it firmly in the vehicle, in an upright position.

USER MANUAL P5500 (2020) POLARIS

FOR MAINTENANCE AND SAFETY

OWNER'S MANUAL

ENGLISH

FRANÇAIS CANADIEN

P5500

P6500

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.

WARNING

Operating, servicing and maintaining this equipment can expose you to chemicals including engine exhaust, carbon monoxides, soots, mineral oils, and lead which are known 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 and operate your equipment in a well-ventilated area and wear gloves or wash hands frequently when servicing your equipment.

For more information go to www.P65Warnings.ca.gov.

FOR MAINTENANCE AND SAFETY

OWNER'S MANUAL

P5500

P6500

POLARIS® and POLARIS POWER® are trademarks of POLARIS Industries Inc.

Copyright 2019 Polaris Industries 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 product 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 product are in English. Other languages are provided as translations of the original instructions.

Printed in China

9931064 Rev 02

Designed in our labs, put to the test in yours.

Power for everything, for everyone. We've designed Polaris Power® with that simple principle in mind. From long weekend camping trips and tailgating to construction sites and power while you wait out the storm, we've got you covered.

Our line of generators are built for it all. No detail too small, no spec overlook. We've redefined the definition of limits, so you can keep redefining yours.

• P2000i Inverter Generator
• P3200iE Inverter Generator
• P5500 Open Frame Generator
• P6500 Open Frame Generator

Your owner's 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 generator best and is interested in your total satisfaction. Your POLARIS dealership can perform all of your service needs during, and after, the warranty period.

Introduction 7

Safety 11

Features and Controls 27

Assembly 35

First Use Instructions 41

Operation 45

Emission Control Systems ..... 59

Maintenance 61

Specifications 85

POLARIS Products 87

Troubleshooting 89

Warranty 93

Maintenance Log 103

INTRODUCTION

OVERVIEW

For a safe and enjoyable operation of your new generator, please read the entirety of this owner's manual. If you should need additional assistance with generator operation or maintenance, please see your Polaris dealer or other certified service technician.

After reading this manual in its entirety, store in a convenient location for future reference.

NOTICE

You must complete the Warranty Registration Form included with your generator and forward it to Polaris within 10 days of purchase. Warranty coverage will not be active unless your generator is registered.

INTENDED USE

The Polaris Power Generator is intended to supply power. Such items include, but are not limited to:

• Furnace fans
• Sump pumps
• Dishwashers
• Hotplates / stoves
• Washing machines
• Garage door openers
• Water heaters
• Refrigerators
• Campers / RVs
• Job site trailers
• Welders
• Circular saws

Items that use more than the recommended amount (see page 85) of combine power consumption should not be connected to this generator.

SAFETY SYMBOLS AND SIGNAL WORDS

The following signal words and symbols appear throughout this manual and on your generator. 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.

ke in

The Mandatory Action Sign indicates an action that NEEDS to be taken to avoid a hazard.

S to

GENERATOR IDENTIFICATION NUMBERS

The engine serial number can be found stamped on the crankcase next to the oil drain plug.

Technical line drawing of a portable electric vehicle chassis with visible wheels, motors, and control panel (no text or symbols)

Record your generator's identification number in the space provided. Remove the spare key and store it in a safe place. A replacement key can be obtained through your Polaris dealer.

Serial Number
Purchase Date

SAFETY

SAFETY WARNINGS

WARNING

Failure to follow recommended precautions and procedures could result in severe injury or death. Always follow all safety warnings on the product, and follow all operation, inspection, and maintenance procedures outlined in this manual.

Understand and follow all inspection and maintenance procedures outlined in this manual. Following these procedures is essential for the generator to remain in safe operating condition.

If the generator is not in use for an extended period of time, turn the ignition switch and fuel valve switch to the OFF position.

WARNING

It is the responsibility of the owner to ensure that all users of this generator fully informed of the safety and operating information prior to use.

OPERATOR SAFETY

WARNING

Operating the generator with worn, damaged, or malfunctioning components could result in serious injury or death. Never start the engine without checkin all of the generator components to be sure of proper operation.

Please take the following precautions, which are essential for proper and safe operation:

• Read and understand all of the safety and operating information in this manual and on all warning and instruction labels before using the generator. Use the generator only as described in this manual and on the product.
• Know how to stop the generator quickly in case of emergency, see page 19 for information on stopping the unit quickly.
• Keep children, pets, and bystanders at a safe distance from the generator.
• Review and understand the use of all generator controls, output receptacles, and connections.
• Be sure that anyone who operates the generator receives proper instruction and reads this manual completely. Do not let children operate the generator.

• Use the generator only for intended purposes.

• Turn off the generator immediately if the unit begins to operate abnormally. After the generator has cooled, disconnect the generator and take to your authorized Polaris dealer.

• While operating the generator, if you experience a headache, fatigue, nausea / vomiting, confusion, or seizures, immediately get to fresh air. Do not delay and do not attempt to shut down the unit.

OPERATING WITHOUT INSTRUCTION

WARNING

Operating this generator without proper instruction increases the risk of severe injury or death.

The operator must understand how to operate the generator safely in proper conditions and environments.

All operators must read and understand the owner's manual and all warning and instruction labels before operating the generator.

Blue circular icon with a white human figure reading a book (no text or symbols)

USING ALCOHOL OR DRUGS

WARNING

Never consume alcohol or drugs before or while operating this generator. Operating this generator after consuming alcohol or drugs could adversely affect operator judgment

BEE BEER

FAILURE TO INSPECT BEFORE OPERATING

WARNING

Failure to inspect and verify that the generator is in safe operating condition before operating increases the risk of an accident resulting in severe injury or death.

Always perform the pre-operation inspection before each use of your generator to make sure it's in safe operating condition.

Always follow the inspection and maintenance procedures and schedules described in this owner's manual.

CARBON MONOXIDE SAFETY

WARNING

Generator exhaust contains Carbon Monoxide (CO) vapors. Exposure to Carbon Monoxide by people or pets can result in SEVERE INJURY or DEATI ALWAYS operate generator according to all warning and instruction labels and this manual.

• This portable generator runs on gasoline. The generator exhaust vapor contains carbon monoxide (CO).
  • Carbon monoxide is odorless. You cannot smell it.
  • Carbon monoxide is colorless. You cannot see it.
• The generator is for outdoor use only. Never run the generator in an enclosure area. Exhaust contains poisonous carbon monoxide vapor that can cause loss of consciousness or death. Operate the generator in an open, and well ventilated area.
• Do not use the generator indoors in garages, basements, crawl spaces, sheds, portable buildings, or similar areas even if doors and windows are open or if ventilating fans are used to circulate air.
• Do not use the generator near windows, doors, vents or any other building openings even if they are closed. Poor seals on a door, as one example, could still permit high levels of carbon monoxide to infiltrate the living area of home.
• Be sure to install approved carbon monoxide detectors in your home that have battery back-up systems that will continue to detect the presence of carbon monoxide during electric-power outages. Test these devices and replace batteries as recommended by their respective manufacturers.

IMPORTANT

If you experience a headache, fatigue, nausea / vomiting, confusion, or seizures, immediately get to fresh air and away from the unit. Do not delay for any reason.

ELECTRICAL SAFETY

! DANGER

This generator produces high voltage electricity sufficient to cause death by electrocution.

• The generator produces enough electric power to cause serious shock or electrocution if misused.
  • Always connect the generator to a suitable ground circuit.
• When servicing the generator, disconnect the spark plug wire and place it where it cannot contact the plug. Turn the engine switch to the OFF positio
• Do not check for a spark with the plug removed. Use only approved spark plug testers.
• Using a generator or electrical appliance in wet conditions, such as rain or snow, or near a pool or sprinkler system, or when your hands are wet, could result in severe shock or electrocution. Keep the generator dry and away from all sources of moisture.
• If the generator is stored outdoors, unprotected from the weather, check all electrical components on the control panel before each use. Moisture or ice can cause a malfunction or short circuit in electrical components that could result in electrocution.
• Do not connect the generator to a building's electrical system unless an isolation switch has been installed that meets applicable electrical codes and regulations.
• To avoid overloading the generator, ensure load is kept within the rated pow range stated on the generator. Overloading will damage the unit and / or shorten its operating lifespan.

NOTICE

Do not attempt to connect generators in parallel.

EXTENSION CORD USE

Read the manufacturer starting and running wattage details and operating instructions for the device(s) and appliance(s) that will be used. Often this information can be found in the owner's manual or on specification decals on the device or appliance.

CHOOSING A PROPER EXTENSION CORD

Polaris recommends using only U.L. (Underwriters Laboratories, Inc.) approved extension cords labeled with the use, size, and wattage rating.

Only use heavy-duty extension cords with a three-prong (grounded) plug for your safety.

Decide on what length extension cord is required as cord length determines the extension cord gauge. Remember, as the cord gets longer, the current capacity of the cord decreases.

Never use an extension cord outdoors that is designated as "indoor use only".

EXTENSION CORD SAFETY

Your generator is equipped with cord holder hookr storage of an extension cord.

Store all extension cords indoors when not in use. Outdoor conditions can deteriorate a cord over time.

Before plugging an extension cord or power cord into the generator, check the cord for signs of damage.

Diagram of a wheeled cart with wheels and a black cable, labeled with number 1 (no text or symbols on the diagram itself)

CAUTION

Do not store an extension cord on the generator while the generator is in use. Hot surfaces from the engine could result in damage to the cord. Wait until generator has been turned off and cooled before storing an extension cord on the hooks.

IMPORTANT

The cord will still conduct electricity until it is unplugged from the outlet.

FIRE SAFETY

WARNING

Gasoline is extremely flammable and is explosive under certain conditions. Do not smoke or allow flames or sparks where generator is refueled or where gasoline is stored. Refuel in a well-ventilated area with the engine OFF.

CAUTION

Generator exhaust system gets hot enough to ignite some materials and burr skin if touched.

• Keep the generator at least 3 feet (1 m) away from buildings, other equipment, and combustible materials during operation.
• Do not enclose the generator in any structure.
• Keep children and pets away from generator.
• Exhaust system components are very hot during and after use. Hot components can cause burns and fire. Do not touch the hot exhaust system components. Always keep combustible materials away from the exhaust system.
• Ensure that any spilled fuel is properly wiped up prior to using the generator as fuel vapors are flammable.

EXPOSURE TO EXHAUST

WARNING

Exhaust fumes from your generator are poisonous and can cause loss of consciousness or death in a short time. Never start the generator or let it run an enclosed area. Only operate this generator while outdoors.

HOT EXHAUST SYSTEMS

WARNING

Exhaust system components are very hot during and after use of the machine. Hot components can cause burns and fire. Do not touch hot exhaust system components. Always keep combustible materials away from the exhaust system.

Use caution when operating near tall grass, especially dry grass. Always inspect the exterior of the generator and areas near the exhaust system before and after use. Promptly remove any grass, debris, or foreign matter clinging to the generator. Pay particular attention to the exhaust system area.

Illustration of a yellow industrial machine component with wheels and motors, no text or symbols present

NOTICE

Do not apply the storage cover to the generator while the engine components are still hot. Wait until generator has sufficiently cooled before covering.

EQUIPMENT MODIFICATIONS

Your POLARIS generator is designed to provide safe operation when used as directed. Modifications to your generator may negatively impact generator stability. Failure of critical machine components may result from operation with any modifications, especially those that increase power.

Do not install any non-POLARIS-approved accessory or modify the generator for the purpose of increasing power output. Any modifications or installation of non-POLARIS-approved accessories could create a substantial safety hazard and increase the risk of bodily injury.

Modifying the generator by adding or removing any parts, components, or any modifications not approved by Polaris may void the warranty. Such modification may make the generator unsafe to operate and could result in severe injury to operators and bystanders, as well as damage to the generator. Some modifications may not be legal in your area. If in doubt, contact your authorize POLARIS dealer.

NOTICE

For more information about safety, call POLARIS at 1-800-342-3764

HANDLING GASOLINE

WARNING

Gasoline is highly flammable and gasoline vapor is explosive under certain conditions. Always use caution when handling gasoline.

• If the generator has been in operation, allow engine to cool completely before refueling.
  • Always store gasoline in an approved container.
  • Always refuel outdoors or in a well-ventilated area away from any combustible materials.
• Do not smoke or allow open flames or sparks in or near the area where refueling is performed or where gasoline is stored.
• Never permit children to handle gasoline.
• Never refuel around bystanders, pets, and flammable objects.
• Loosen the fuel cap slowly to relieve pressure in the tank.
  • Take care not to overfull or spill any fuel on the generator or muffler when refueling.
• If gasoline spills on skin or clothing, immediately wash it off with soap and water and change clothing.
• Do not use the generator if you observe leaking gasoline. Have the generator serviced immediately and before using it again.
• When operating or transporting the generator, be sure it is kept upright. If it tilts, fuel may leak. Be sure the fuel tank cap is tightened when transporting the generator.
• Do not refuel using gas station pumps.
• Remove fuel from the generator before transporting in a vehicle.

WARNING

Always operate generator on level surface. If the generator is tilted, fuel may spill or the generator may tip over, causing hazardous conditions. Do not swallow gasoline, inhale gasoline vapors, or spill gasoline. If you swallow gasoline, inhale more than a few breaths of gasoline vapor, or splash gasoline in your eyes, see a physician immediately. If gasoline spills on skin or clothing, immediately wash it off with soap and water and change clothing.

OPERATION RULES

• Perform all Pre-Operation Inspection activities as shown on page 44 of this manual. Inspect and tighten all parts before each use. Ensure the generator does not have any damaged, loose, or missing parts before use. All defects should be corrected before use. Do not operate the generator if it has been dropped or damaged until all defective parts have been repaired.
• Do not place any flammable materials near the generator.
• Never start the generator or let it run in an enclosed area. Exhaust vapors poisonous and can cause loss of consciousness or death in a short time. Keep the generator away from buildings and other equipment during operation.
• Do not operate the generator in exposed locations where it will be subjected to wet conditions.
• Do not touch the generator with wet hands, as this may cause severe electric shocks.
• Do not pour water directly over the generator or wash it.
• Do not use or store the generator in the rain or snow.
• Do not cover the generator when in use.
• Always operate the generator on a firm, flat, and level surface, as the generator will vibrate on an irregular surface.
• If the generator is tilted, fuel may spill or the generator may tip over, causir hazardous situation. Lock the wheels before using.
• Do not connect the generator to another power supply source.
• The engine becomes extremely hot during and immediately after it has been in use. Be careful not to touch any parts of the hot engine, especially the muffler or muffler cover, or serious burns may result.
• Do not connect external equipment to the generator before starting the engine.
• Do not use for life support, or life sustaining systems.

NOISE LEVEL

The following noise chart lists average decibel levels for everyday sounds and appliances.

DANGER LEVEL	SOUND DECIBEL	LEVEL	PERMISSIBLE EXPOSURE TIME	SAFETY RECOMMENDATION
Painful Impulse Noise	Fireworks (3 ft) / Shotgun Blast	150 dBP	Not safe for any period of time.	Avoid exposure. Not safe for any period of time.
	Firearms 140 dBP	Not safe for any period of time.
Painful Steady Noise	Jackhammer 130	dB(A) Not safe for any period of time.
	Jet Plane Takeoff / Siren	120 dB(A)	Not safe for any period of time.
Extremely Loud	MP3 Player Max Output / Rock Concert	112 dB(A)	~ 1 minute Wear earplugs or earmuffs.
	Leaf Blower / Snow Blower	106 dB(A)	> 4 minutes
	Hair Dryer / Blender	94 dB(A)	1 hour
Very Loud Passing	motorcycle / Gas Lawn Mower	91 dB(A)	2 hours
Loud Busy Traffic / Vacuum Cleaner		85 dB(A)	8 hours No protection	required.
Moderate Generator / Group Conversation		70 dB(A)	Unlimited
		60 dB(A)	Unlimited
		50 dB(A)	Unlimited
		40 dB(A)	Unlimited
Faint Whispering	30 dB(A)	Unlimited

HEARING PROTECTION

Earmuffs are worn over the ears. They must completely surround the ear and snugly to reduce sound. Quality earmuffs, worn properly, can block up to 30 decibels of noise.

Earplugs are inserted into the ear to completely block the ear canal. Quality earplugs can reduce noise by up to 30 decibels.

SAFETY LABELS AND LOCATIONS

Warning labels have been placed on the generator for your protection. Read and follow the instructions on each label carefully. If any of the labels shown in this manual differ from the labels on your generator, always read and follow the instructions of the labels on the generator.

If an informational or graphic label becomes illegible or comes off, contact your POLARIS dealer to obtain a replacement. Replacement safety labels are provided by POLARIS at no charge.

Technical diagram of a vehicle chassis with numbered components for identification

① General Warning

② Carbon Monoxide Danger

③ Hot Exhaust Caution

GENERAL WARNING

The general warning is located on the top side of the generator near the fuel volume indicator.

WARNING

Improper generator use can result in SEVERE INJURY or DEATH. Read the owner's manual. Follow all instructions and warnings.

Gasoline is flammable and explosive. Severe burns can result.

ALWAYS stop the engine and let cool down before refueling.

ALWAYS check for fuel leaks and wipe up any spills.

ALWAYS turn the fuel to OFF when not in use.

NEVER handle gasoline indoors. NEVER overfill the fuel tank.

Generator exhaust contains poisonous Carbon Monoxide (CO) vapors.

ALWAYS operate in a well-ventilated area.

NEVER operate in a home, garage, enclosed area near windows, doors, or people.

NEVER operate near flammable objects.

Electrocution can result from using generator in rain, snow, near water, with wet hands, or with improper connections.

ALWAYS keep generator and surrounding area dry.

NEVER connect generator to any building without electrical-isolation protection that meets applicable codes and regulations.

Black silhouette of a flame with flame-like patterns (no text or symbols)

Abstract black-and-white illustration of a human head with a dotted pattern and a circular object, no text or symbols present.

CARBON MONOXIDE WARNING

The carbon monoxide warning label is located on the top side of the generator near the fuel level indicator.

DANGER

Using a generator indoors CAN KILL YOU IN MINUTES.

Generator exhaust contains carbon monoxide. This is a poison you cannot see or smell.

NEVER use inside a home or garage. EVEN IF, doors and windows are open.

Diagram showing two house symbols with prohibition signs, indicating no restrictions on either document or vehicle.

Only use OUTSIDE and far away from windows, doors, and vents.

Simple line drawing of a house with a window and a printer icon showing an arrow (no text or symbols)

HOT EXHAUST CAUTION

The hot exhaust caution is located on the top side of the gas tank near the fue volume indicator.

CAUTION

Contacting a hot exhaust system can cause serious burns. Do not touch if generator is or has been running.

Silhouette of a hand with five fingers extended (no text or symbols)

FEATURES AND CONTROLS OVERVIEW

Technical diagram of a lawn mower with numbered parts for identification

COMPONENT DESCRIPTION
1 Fuel Tank Cap	Provides access to the fuel tank.
2 Air Filter	Filter impurities from the air to reduce wear of engine.
3 Engine Oil Indicator Dipstick	Provides access to oil tank and measures oil level.
4 Fuel Gauge	Provides indication of fuel level.
5 Control Panel	Contains the switches, buttons, indicator panel, and receptacles for proper operation of the generator.
6 Recoil Starter	Causes the recoil starter to crank the engine when pulled.
7 Battery	Operates the electric components of the generator, including electric start and indicator panel.
8 Gas Tank	Contains the fuel supply to operate the engine
9 Air Intake	Provides air to cool the engine.
10 Wheel Locks	Locks rear wheels to inhibit motion of the generator.
11 Lift Mount	Allows for vertical suspension of the generator.
12 Spark Plug	Ignites fuel and air mixture to start engine.
13 Air Exhaust	Dispels exhaust air from cooling the engine.
14 Muffler	Reduces noise and emissions from engine combustion.

the

CONTROL PANEL

Diagram of a device rear panel with numbered components and labeled connectors

① Fuel Valve Switch
② Ignition Key Switch
③ Electric Start Circuit Breaker
④ Indicator Light
⑤ Hour Meter
⑥ DC Circuit Breaker

⑦ DC Receptacle
⑧ Ground Terminal
⑨ 240V Circuit Breaker
⑩ AC Receptacles
⑪ AC Circuit Breakers
⑫ 120V / 240V AC Twist-Lock Receptacle

FUEL VALVE SWITCH

The fuel valve switch controls the ignition system and the fuel valve. When the engine is well-cooled and not in use, the fuel valve must be placed in the OF position to reduce the possibility of fuel leakage.

The switch must be in the ON position to allow the engine to operate.

Diagram showing a green curved arrow pointing to a yellow circular component with a handle, surrounded by circular elements (no text or symbols)

① ON: opens the fuel valve and allows the engine to be started.

Diagram showing a yellow circular component with green curved arrow and numbered circles (no text or symbols)

② OFF: closes the fuel valve and shuts off the engine.

IGNITION KEY SWITCH

The ignition switch① must be in the ON / RUN position for the generator to operate.

Diagram of a device's front panel with labeled components and a yellow circular component, marked with number 1.

INDICATOR LIGHT

The indicator light will illuminate GREEN when the engine is running.

Close-up of a yellow spherical object with threaded end and labeled point 1, against a white background (no text or symbols beyond labels)

IMPORTANT

The overload reset button is available for a maximum of 5 times for each first start of the generator. Shut down the generator and restart using power switch in order to refresh number of resets.

CHOKE LEVER

Technical line drawing of a mechanical component with no visible text or symbols

Using the choke lever provides proper fuel-starting mixture when the generator's engine is cold. When attempting to start a cold engine, turn the lever to the left (CLOSED). Return the lever to the starting position (OPEN) once the engine has warmed.

FUEL VOLUME INDICATOR

The Fuel Volume Indicator provides an indication of fuel quantity.

Diagram of a yellow plastic component being inserted into a housing, with an inset magnified view highlighting the component (no text or symbols present)

STARTER RECOIL GRIP

NOTICE

Do not allow starter grip to snap back against the generator. Return it prevent damage to the starter. The starter recoil grip causes the recoil start to crank the engine when pulled.

Technical illustration of a vehicle's front wheel assembly with a highlighted yellow component (no text or symbols)

The recoil starter is used as a secondary engine starter if the battery does not contain adequate charge to operate the electric starter.

GROUND TERMINAL

NOTICE

Consult a qualified electrician, electrical inspector, or local agency having jurisdiction for local codes or ordinances for the intended use of the generator before using the ground terminal.

Diagram showing a green mechanical component with a magnified inset highlighting its threaded body (no text or symbols present)

The ground terminal connects to the frame of the generator, metal parts that do not conduct current, and ground terminals of each receptacle.

The circuit breaker will automatically switch off if a short circuit or significant overload of the generator occurs to the 240V receptacle.

If the circuit breaker switches OFF automatically, check that all connected appliances are working properly and do not exceed the generator's maximum output before switching the breaker back to the ON position.

nt e 1 2

120V CIRCUIT BREAKERS

Diagram of a computer monitor panel with labeled buttons and ports, showing numbered labels 1 to 4.

The 120V circuit protectors automatically shut off current to receptacles when circuit is overloaded or when there is a problem with the DC battery charging circuit.

① Electric Start Circuit Breaker
② DC Circuit Breaker
③ AC Circuit Breaker - Left

Receptacles

④ AC Circuit Breaker - Right Receptacles

AC RECEPTACLES

The AC receptacles provide four connections for properly rated AC appliances.

Illustration of two yellow electrical connectors with mounting holes and a white terminal block (no text or symbols)

120V / 240V AC TWIST LOCK RECEPTACLE

The twist-lock AC receptacle® provides connection for properly rated, 120V and 240V AC appliances.

Illustration of a yellow circular object suspended above a wall-mounted device (no text or symbols)

P5500I P6500I
VOLTAGE AMPAGE VOLTAGE AMPAGE
120 V 46 amps 120	V 54 amps
240 V 23 amps 240	V 27 amps

DC RECEPTACLE

The DC receptacle charges 12V DC automotive-type batteries. The DC chargin output is not regulated.

This receptacle is protected from an overload with a circuit protector. If the DC circuit is overloaded, the protector will open and power to the DC receptacle will cease.

The protector is located above the receptacle and is closed by pressing down on the button.

3D rendered geometric shape resembling a hexagonal prism with two internal cutouts (no text or symbols)

ASSEMBLY

IMPORTANCE OF PROPER ASSEMBLY

WARNING

Improper assembly can cause an unsafe condition that can lead to serious injury or death. Follow the assembly procedures and precautions in this manual carefully.

Proper assembly is essential to operator safety and the reliability of your generator. Errors and oversight made during unit assembly or service could result in faulty operation, damage to the machine, or operator injury.

UNBOXING

1. Remove generator and loose parts from the box.
2. Compare loose parts to the inventory list below.

NOTICE

Contact your dealer if any of the loose parts listed below are not inclu your generator.

REF. NO.	DESCRIPTION QUANTITY
1	Wheel 4
2	Axle 2
3	Washer 4
4	Spacer 4
5	E-Clip 4
6	Right Wheel Lock 1
7	Left Wheel Lock	1
8	2 in Flange Bolt 4
9	Lift Mount	1
10	Flange Nut	4
11	3 in Flange Bolt 4

Illustrated guide showing a sequence of mechanical components with numbered labels, including parts like rings, rods, and tools.

OTHER INCLUDED ITEMS

Inside your generator box, there should be the following items:

• Owner's manual
• Oil funnel
  • Warranty registration form

WHEEL KIT

Technical diagram of a vehicle's wheel assembly with numbered parts for identification

PARTS

REF. NO.	DESCRIPTION QUANTITY
1	Axle 2
2	Spacer 4
3	Wheel 4
4	Washer 4
5	E-Clip 4

ASSEMBLY

1. Insert axles① through front and rear busings on generator frame.

2. Slide a space② onto the axle.

3. Slide wheel③ onto axle.

4. Place washer④ against outer bushing.
5. Secure the wheel by inserting an E-clip ⑤ into groove on axle.

3D diagram showing a yellow pipe with a purple downward arrow and a green circular component, labeled with number 5 (no text or symbols on the diagram itself)

WHEEL LOCKS

Technical diagram of a vehicle chassis with wheels and air vent, no text or symbols present

PARTS

REF. NO. DESCRIPTION QUANTITY
6	Right Wheel Lock 1
7	Left Wheel Lock 1
8	2 in Flange Bolt 4

ASSEMBLY

1. Attach right wheel lock to right rear bracket and align holes.
2. Insert bolt⑧ through each hole.
3. Tighten bolt to specified torque.

Repeat process for left wheel lock

Illustration of a yellow mechanical clamp device with attached metal bracket and two hanging weights, no text or symbols present.

TORQUE

2 in Flange Bolt

8 ft-lbs (10.85 N·m)

LIFT MOUNT (OPTIONAL)

Technical diagram of a yellow mechanical component with numbered parts labeled 9, 10, and 11

PARTS

REF. NO. DESCRIPTION QUANTITY
9	Lift Mount Handle 1
10	Flange Nut 4
11	3 in Flange Bolt 4

ASSEMBLY

1. Slide lift mount handle® under the frame and align with bolts.
2. Insert bolt ^⑪ through each bearing on generator frame.
3. Screw nut ^10 onto each bolt and tighten to specified torque.

TORQUE

Flange Nuts16 ft-lbs (21.69 N·m)

FIRST USE INSTRUCTIONS

ADDING ENGINE OIL

NOTICE

Failure to use the recommended 4-stroke engine oil may result in engine damage.

FLUID CAPACITY

Polaris 5W-30 Generator Oil

37.2 fl oz (1100.1 mL)

Technical illustration of a vehicle chassis with red spray canister and yellow hose, no text or symbols present

1. Place generator on flat, level surface.
2. Remove the oil filler cap / dipstick.
3. Fill the engine crankcase with the specified amount.
4. Insert the dipstick into the filler neck, without screwing it in.
5. Remove the dipstick and verify that the oil level is at the upper limit. The should not reach above the threading. Add additional oil and inspect the level as needed until the upper limit has been reached.
6. Re-install the dipstick. Use a clean shop rag to clean any spilled oil.

FUEL

FUEL RECOMMENDATION

Polaris recommends the use of 87 octane fuel or higher.

WARNING

Gasoline is highly flammable and explosive and can cause serious injury or death. Stop the engine and keep heat, sparks, and flame away. Handle fuel only outdoors. Wipe up spills immediately.

CAUTION

Never use stale or contaminated gasoline or an oil /gasoline mixture. Avoid getting dirt or water in the fuel tank.

Do not spill fuel when filling the fuel tank. Damage caused by spilled fuel is not covered under warranty. Spilled fuel is a fire hazard, causes environmental damage, and can damage paint and plastic. Wipe up spills immediately. Do not fill above bottom of strainer.

Refuel in a well ventilated area before starting the engine. If the engine has been running, allow it to cool.

Never refuel the engine inside a building where vapors may reach flames or sparks. Keep fuel vapors away from electrical appliances.

CAUTION

Do not use fuel containing more than 10% ethanol. If the content of ethanol exceeds the specified limits, it may cause starting or performance problems. It may also damage metal, rubber, and plastic parts of the fuel system. Do not use gasoline containing methanol. Damage due to ethanol or methanol is not covered under warranty.

IMPORTANT

Operating the generator with an obstructed fuel system will result in serious engine damage. Perform maintenance as recommended.

Thoroughly read “Safety” section and all safety information when handling fuel. In order to insure the optimum output and the maximum service life of the generator, the generator should run at a 50% load for the first 20 hours.

ADDING FUEL

WARNING

Gasoline is highly flammable and gasoline vapor is explosive under certain conditions. Improper gasoline handling could result in severe injury or death. Always use caution when handling gasoline.

To safely add fuel to the gas tank, perform the following steps.

1. Ensure fuel valve switch is OFF.
2. Remove the fuel tank cap.
3. Fill carefully to avoid spilling fuel on the fuel tank strainer. Do not overfill the fuel tank (there should be no fuel above the upper limit mark).

WARNING

Do not overfill. Fuel overflow may spill onto a hot engine and result in fire or explosion.

Line drawing of a lawn mower with labeled components (no text or symbols beyond labels)

1. Tighten fuel tank cap securely.
2. Position fuel switch to OFF for storage or ON to operate the generator.
3. Move generator away from fueling source and site before starting engine.

Gasoline is highly flammable and explosive and can cause serious injury or death. Stop the engine and keep heat, sparks, and flame away. Handle fuel only outdoors. Wipe up spills immediately.

CAUTION

Failure to perform the recommended pre-operation inspections could result in minor or moderate injury or property damage. When inspection reveals the need for adjustment, replacement, or repair, perform service promptly or visit your authorized Polaris dealer for assistance.

CAUTION

If the engine has been running, the muffler will be very hot. Allow the cool before servicing.

muffler t

IMPORTANT

Always perform the recommended pre-operation inspections before each and when removing the generator from storage.

use

ITEM REMARKS PAGE
Engine Oil Check and add oil, as needed. See page 41and page 68.
Fuel Level Check the fuel level and refuel, as needed.		See page 45.
Exhaust System	Inspect the exhaust system for leakage.Tighten or replace gasket, as needed.	See page 74.
Carburetor Inspect choke knob operation. See page 31.
Level Ground Ensure the generator is resting on a level surface to prevent spills or tipover.		-
Wheel Lock Lock the wheels prior to operation. See page 46.
Grass and Leaves	Remove grass, leaves, and other flammable material or debris, especially near the HOT exhaust system.	See page 18.

OPERATION

SAFE OPERATING PRECAUTIONS

REFUELING

WARNING

Gasoline is highly flammable and explosive and can cause serious injury or death. Stop the engine and keep heat, sparks, and flame away. Handle fuel only outdoors. Wipe up spills immediately. Thoroughly read the Safety chapter of this manual before handling fuel.

CAUTION

Do not spill fuel when filling the fuel tank. Damage caused by spilled fuel is covered under warranty. Spilled fuel is a fire hazard, caused environmental damage, and can damage paint and plastic. Wipe up spills immediately. Do n fill above bottom of strainer.

Refuel in a well ventilated area before starting the engine. If the engine has been running, allow to cool before refueling.

Never refuel the engine inside a building where vapors may reach flames or sparks. Keep fuel vapors away from electrical appliances.

Do not overfill the fuel tank (there should be no fuel in the filler neck). After refueling, make sure the fuel filler cap is closed properly and securely.

To safely refuel the gas tank, perform the following steps.

1. Ensure fuel valve switch is OFF.
2. Remove fuel tank cap.
3. Fill carefully to avoid spilling fuel on the fuel tank strainer. Do not overfill the fuel tank (there should be no fuel above the upper limit mark).

WARNING

Do not overfill. Fuel overflow may spill onto a hot engine and result in fire explosion.

1. Tighten fuel tank cap securely.
2. Position fuel valve switch to OFF for storage or ON to operate the generate
3. Move generator away from the fueling site and fuel source before starting t engine.

WHEEL LOCKS

IMPORTANT

Always engage the wheel locks prior to operation to ensure generator stability.

Diagram showing a mechanical device with a green arrow indicating rotational motion, labeled with number 1

Engage the wheel lock by pulling the hand firmly downward. To release the lock, pull the handle upward.

STARTING THE ENGINE

! DANGER

Never operate a generator indoors. Engine exhaust contains carbon monoxide, an odorless, colorless gas that can kill you within minutes. Always use this generator outdoors in a well-ventilated area.

WARNING

Before starting the engine, take the following precautions:

• Ensure the generator is away from the fueling source.
• The generator will vibrate during operation. Place the generator in a dry location and on a flat, level surface.
• Unplug all power cords and extension cords from the generator.
• Engage the wheel locks (if installed).
• Perform an oil, fuel, and air filter check.

ELECTRIC START

1. Ensure the generator is away from the fueling source.
2. Unplug all power cords and extension cords from the generator.
3. Position the fuel switch to ON.
4. For a cold engine start, position the choke lever to CLOSED. To restart a warm engine, leave the choke lever to OPEN.
5. To start the generator using the ignition key, turn the ignition switch to the START position. When the engine starts, release the key. Do not operate the starter for more than 10 second intervals. If it doesn't start turn the key to the OFF position for 5 seconds before repeating until it starts.

Diagram showing a yellow object with a mechanical component and a numbered circle (1), no readable text or symbols present.

n art r 5 2

① OFF
② ON

RECOIL START

1. To start the generator using the recoil, lightly pull the starter recoil grip ① until resistance is felt. Then, firmly pull straight out.

NOTICE

Do not allow starter grip to snap back against the generator. Return it gently to prevent damage to the starter.

LWLD 1

1. For a cold engine start, turn choke lever to CLOSED position.
2. If the choke lever was positioned to CLOSED to start the engine, move it to OPEN as the engine warms up.

STOPPING THE ENGINE

NOTICE

Continually stopping the generator with a load applied can lead to damage of the control module.

In case of emergency, turn ignition key to OFF position to stop the engine. Unde normal conditions, perform the following procedure:

1. Shut off or disconnect all appliances connected to the generator.
2. Turn ignition key switch to OFF.
3. Turn fuel valve switch to OFF.

AC OPERATION

WARNING

Before connecting a device or power cord to the generator, ensure it is in good condition. Faulty appliances or power cords can create a potential for electrical shock.

If an appliance begins to operate abnormally, becomes sluggish, or suddenly stops, immediately shut it off. Disconnect the appliance and determine whether the problem is the appliance or if the rated load capacity of the generator has been exceeded.

Ensure the combined electrical rating of the device or appliance does not exceed the maximum allowed by the generator. Never exceed the maximum power rating of the generator. Do not exceed the current limit specified for an one receptacle. Power levels between rated and maximum may be used for more than 30 minutes.

IMPORTANT: Before connecting a device or power cord to the generator, ensure the device or cord is in good condition and electrical rating does no exceed the maximum amount allowed by the generator.

FOLLOW DIRECTIONS SAVEZ INSTRUCTION 1

1. Start engine. See page 47 for additional instruction.
2. Confirm the desired appliance is switched off. Then plug the appliance or extension cord into one of the AC receptacles
3. Turn on the appliance.

NOTICE

Should the generator's maximum load of 25 amps be exceeded, the circuit protection device will trip and cut all current to the receptacles. The engine will continue to run. Correct the load by unplugging all appliances from the receptacles and press-in the circuit protector button to reset, followed by the Overload Reset button. AC power will be restored immediately.

AC CAPACITY

MODEL MAX POWER	RATED POWER
P5500 5500 W 5000 W
P6500 6500 W 6000 W

NOTICE

In case of substantial overloading, the electronic circuit protector will activate. Slightly overloading the generator or running at maximum power operation (30 minutes) may not switch the circuit ON, but will shorten the service life of the generator.

Consider total power requirements of all connected devices. Appliance and power-tool manufacturers typically list rating information near the model or serial number. After plugging in a device, allow the generator to stabilize before plugging in additional items. Always consider generator capacity before plugging in any device.

Typical wattages are listed in the table below. Before plugging any device into the generator, verify the manufacturer-listed wattage on the device.

WATTAGE REFERENCE TABLE

DEVICE RUNNING (RATED)	WATTS ADDITIONAL STARTING(SURGE) WATTS
Table Saw / Radial Arm Saw 10"	-2000 2000
Space / Wall Heater 1800 0
Central Air Conditioning 1500	4500
Circular Saw - 7 1/4" 1400 2300
Hair Dryer 300 - 1200 0
Sump Pump - 1/2 HP 1050 2200
Microwave Oven - 100 Watt	1000 1400
Coffee Maker	1000 0
Garage Door Opener 1/2 HP	875
Personal Computer w/ 17" Monitor	800
Refrigerator	400 - 800
Dehumidifier	650
Color Television - 27" 500	0
Electric Drill - 3/8", 4 amps	440
Paint Sprayer	360
Radio	300
Oven	60
Light Bulb - 75 Watt	75

POWER MANAGEMENT EXAMPLE

DEVICE RUNNING (RATED)	WATTS ADDITIONAL STARTING(SURGE) WATTS
Circular Saw 1400 2300
Halogen Work Light 1000 0
AM/FM Radio 100 0

2500 = Total Running (Rated) Watts

2300 = Additional Starting (Surge) Watts

4800 = Total Generator Output Required

CAUTION

Ensure the combined electrical rating of the powered device(s) do not exceed the maximum output allowed by the generator. Never exceed the maximum power rating of the generator. Power levels between rated and maximum may be used for no more than 30 minutes.

DC OPERATION

The DC Receptacle on this generator is designed to charge 12V DC batteries. is not designed to operate DC motors.

CAUTION

This generator is not designed to operate DC motors. The DC charging output is not regulated. The DC receptacle should only be used for charging 12V D batteries. Output voltage is 15-30V.

The DC output is to be used to charge batteries only. Serious damage to the stator windings can occur if connected to a DC motor or transformer.

BATTERY CHARGING

WARNING

The battery emits explosive hydrogen gas during normal operation. A spark of flame can cause the battery to explode with enough force to kill or cause serious injury. Wear protective clothing and eye protection when charging a battery. Failure to adhere to these safety precautions could lead to severe injury or death.

Battery posts, terminals, and related accessories contain lead and lead components. Wash hands after handling.

To prevent the possibility of creating sparks near the battery, connect the charging cable first to the generator then to the battery. Disconnect the cable first at the battery.

The battery contains sulfuric acid (electrolyte). Contact with skin or eyes may cause severe burns. Wear protective clothing and a face shield. If electrolyte gets on your skin, flush with water. If electrolytes get in your eyes, flush with water for at least 15 minutes and call a physician.

Electrolyte is poisonous. If swallowed, drink large quantities of water or milk and follow with milk of magnesia or vegetable oil and call a physician. Keep of reach of children.

CONNECTING THE BATTERY CHARGING CABLE

1. Disconnect the ground cable from the negative (-) battery terminal, followed by the positive (+) cable.

2. Plug the battery charging cable into the DC receptacle.

Simple 3D-rendered white object with two vertical slots, no text or symbols visible

1. Connect the red lead of the battery charging cable to the positive (+) battery terminal and then the black lead to negative (-) battery terminal. Do not reverse the charging cables or serious damage to the generator and/or battery may occur.
2. Start the generator.

NOTICE

The DC receptacle may be used while the AC power is in use.

CAUTION

Do not start the vehicle while the battery charging cable is connected and the generator is running. The vehicle's charging system or the generator may be damaged.

DC CIRCUIT OVERLOAD

The DC receptacle is protected from an overload with a circuit protector. If the DC circuit is overloaded, the protector will trip and power to the DC receptacle will cease.

If the circuit protector keeps tripping, discontinue charging and see your authorized Polaris generator dealer.

NOTICE

The circuit protector does not prevent overcharging of the battery.

DISCONNECTING THE BATTERY CHARGING CABLE

1. Stop the generator.
2. Disconnect the black lead of the battery charging cable from the negative (-) battery terminal and then the lead from the positive (+) battery terminal.
3. Unplug the battery charging cable from the DC receptacle.
4. Connect the vehicle battery ground cable to the positive (+) battery terminal.
5. Connect the vehicle battery ground cable to the negative (-) battery terminal.

AIR CONDITIONING OPERATION

Bring the generator to a normal operating temperature before applying the air conditioning load. Always allow a two-minute wait period when manually cycling an air conditioner off and on.

A longer wait period may be required under unusually hot weather conditions. other loads should be turned off until the air conditioner has started and is performing normally.

Before applying an air conditioning load, ensure that your generator is rated to handle to the load. Use the table below and the formula included in the AC Operation chapter for reference.

AC OUTPUT RUNNING (RATED) WATTS ADDITIONAL STARTING(SURGE) WATTS
Window AC - 10,000 BTU 1200 3600
Window AC - 12,000 BTU 3250 9750
Central AC - 10,000 BTU 1500 4500
Central AC - 24,000 BTU 3800 11400
Central AC - 40,000 BTU 6000 18000

NOTICE

Follow the air conditioner manufacturer's instructions for starting and restarting for proper operation. Some air conditioner manufacturers offer a start capacitor as an extra cost option.

The lack of a start capacitor can cause the air conditioner to draw too high starting current and overload the generator. Contact your air conditioner dealer if you consistently have problems starting your air conditioner with the generator.

STANDBY POWER

CONNECTIONS TO A BUILDING ELECTRICAL SYSTEM

WARNING

Improper connection to a building electrical system can allow current from the generator to back feed into the utility lines. Such back feed may electrocute utility company workers or others who contact the lines during a power outage. Additionally, the generator may explode, burn, or cause fires when utility power is restored. Consult the utility company or a qualified electrician prior to making any power connections.

Connections for standby power to a building's electrical system must be made by a qualified electrician and must comply with all applicable laws and electrical codes. Improper connections can allow electrical current from the generator to back feed into the utility lines.

Such back feed may electrocute utility company workers or others who contact the lines during a power outage; when utility power is restored, the generator may explode, burn, or cause fires in the building's electrical system. Do not connect this generator to an automatic transfer switch. Serious damage to the engine and inverter module may result.

In some areas, generators are lawfully required to be registered with local utility companies. Check local regulations for proper registration and usage procedures.

GROUND SYSTEM

This generator is equipped with a system ground to prevent electrical shock from faulty appliances.

To ground this generator, perform the following steps:

1. Ensure engine is OFF and fuel valve switch is OFF.
2. Using a mallet, drive a grounding rod 4 ft. into the ground.

3. Wrap a length of bare copper grounding wire tightly around the grounding rod or use a grounding clamp.

4. Slightly loosen bolt on ground terminal. Allow enough space to wrap copper wire.

5. Using the other end of the copper wire, tightly wrap the wire around the terminal.

Close-up of a yellow plastic component with a magnified inset showing its internal structure (no text or symbols visible)

SYSTEM REQUIREMENTS

There may be federal or state Occupational Safety and Health Administration (OSHA) regulations, local codes, or ordinances that apply to the intended use of the generator. Please consult a qualified electrician, electrical inspector, or the local agency having jurisdiction.

If the generator is used at a construction site, there may be additional regulatory requirements.

USING THE LIFT MOUNT

NOTICE

Always connect lifting equipment to the frame of the generator using the lift mount. Prior to lifting, ensure the lift rigging and supporting structure are in good condition and are rated to lift the load. Never hook lifting equipment to engine or alternator lifting lugs.

For lift mount assembly instructions, see page 40.

Line drawing of a portable electric vehicle with a crane hook attached (no text or symbols)

CAUTION

Never walk or stand under a suspended generator. Impact from a falling generator could result in severe injury or death.

HIGH ALTITUDE USE

CARBURETOR MODIFICATION

NOTICE

When carburetor has been modified for high altitude operation, the air-fuel mixture will be too lean for low altitude use and may cause engine damage. At high altitude, the standard carburetor air-fuel mixture will be excessively rich. Performance will decrease and fuel consumption will increase. A very rich mixture will also foul the spark plug and cause hard starting. Operation at an altitude different than that which this engine was certified, for extended periods of time, may increase emissions.

High altitude operation can be improved by specific modifications to the carburetor. If always operating the generator at altitudes above 3000 feet (915 meters), have an authorized Polaris servicing dealer perform the carburetor modification. The engine will meet each emission standard throughout its life when operated at high altitude with the carburetor modifications for high altitude operation.

With the carburetor modification, engine horsepower will decrease by about 3.5% for every 1000 feet (300 meters) increase in altitude. The effect of altitude on horsepower will be greater if no carburetor modification is made.

CAUTION

Operation of the generator at an altitude lower than the carburetor is jetted for may result in reduced performance, overheating, and serious engine damage caused by an excessively lean air/fuel mixture. Be sure to have any modification reversed at lower altitudes.

ALTITUDE KITS

For added convenience, POLARIS offers high altitude kits which optimize performance and fuel consumption at various altitude ranges. For installation instruction, see page 69.

MODEL PART	NUMBER DESCRIPTION
P2000i 2884865	K-HIGH,ALT,3-8K,P2000I
P3200iE 2884866	K-HIGH,ALT,3-8K,P3200IE
P5500 / P6500	2884867 K-HIGH,ALT,3-8K,P5500/6500

Exhaust gas contains carbon monoxide, nitrous oxide (NOx), and hydrocarbons. It is very important to control the emissions of NOx and hydrocarbons as they are a major contributor to air pollution. Carbon monoxide is a poisonous gas. The emission of fuel vapors is a source of pollution as well. The generator engine utilizes a precise air-fuel ratio and emission control system to reduce the emissions of carbon monoxide, NOx, hydrocarbons, and evaporative fuel emissions.

Polaris utilizes appropriate air-fuel ratios and other emissions control systems to reduce the emissions of carbon monoxide, oxides of nitrogen, and hydrocarbons. In addition, Polaris fuel systems utilize components and control technologies to reduce evaporative emissions.

U.S. AND CALIFORNIA CLEAN AIR ACTS

Your engine has been designed to meet current Environmental Protection Agency (EPA) and the California Air Resources Board (CARB) clean air standards. The regulations dictate that the manufacturers provide operation and maintenance standards regarding the emission control system. Tune up specifications are provided in the Maintenance section. Adherence to the specified maintenance instructions is essential for your engine to meet the emission control standards.

ALTERATIONS

Altering the emission control system may increase emissions beyond the legal limit. Some possible alterations are removal or alteration of any part of the intake, fuel, or exhaust systems.

PROBLEMS AFFECTING EMISSIONS

If aware of any of the following, have the engine inspected and repaired by a authorized Polaris dealer:

• Hard starting or stalling after starting
• Rough idle
• Shut down or backfire after applying an electrical load
  • Afterburning (backfiring)
• Black exhaust smoke or high fuel consumption

REPLACEMENT PARTS

The emission control system on the engine was designed, built, and certified to conform to applicable emission regulations. We recommend the use of Polaris Genuine parts whenever maintenance is performed. These original-design replacement parts are manufactured to the same standards as the original parts. The use of replacement parts that are not of the original design and quality may impair the effectiveness of the emission control system.

Aftermarket part manufacturers assume the responsibility that the part will not adversely affect emission performance. The manufacturer or re-builder of the part must certify that use of the part will not result in a failure of the engine to comply with emission regulations.

MAINTENANCE

IMPORTANCE OF MAINTENANCE

Good maintenance is essential for safe and economical operation. Proper maintenance will also help reduce air pollution. Always follow the recommendations for inspection and maintenance as specified in this manual.

WARNING

Improper maintenance, or failure to fix problems prior to operation, could lead to generator malfunction resulting in serious injury or death.

The following chapter includes a periodic maintenance schedule, including proper inspection and maintenance procedure. The maintenance schedule applies to normal operating conditions. This maintenance is essential to the longevity of your generator.

Any qualified repair shop or person may maintain, replace or repair the emission control devices or systems on your generator. POLARIS also recommends POLARIS parts for emissions-related service, however equivalent parts can be used.

IMPORTANT

It is a potential violation of the Clean Air Act if a part, supplied by an aftermarket parts manufacturer, reduces the effectiveness of the generator's emission controls. Tampering with emission controls is prohibited by federal law.

Owners are responsible for performing the scheduled maintenance identified in this owner's manual. Careful periodic maintenance will help keep your generator in safe, reliable condition. Inspect, clean, lubricate, adjust and replace parts as necessary. Other, more difficult tasks, require special tools and expertise provided by an authorized Polaris technician or other qualified mechanic.

If the generator is operated under unusual conditions, such as sustained high load or high temperature, or dusty conditions, consult the servicing dealer for applicable recommendations.

All necessary replacement parts and labor incurred, with the exception of authorized warranty repairs, become the responsibility of the registered owner. If, during the course of the warranty period, part failures occur as a result of owner neglect in performing recommended regular maintenance, the cost of repairs are the responsibility of the owner.

TOOL KIT

This generator is packaged with a tool kit to help with basic repair and maintenance.

Labeled photo of six different types of electrical connectors and components, numbered 1 to 6.

REF. NO.	TOOL DESCRIPTION QUANTITY
1	12V DC Cable 1
2	Spark Plug Wrench 1
3	Spark Plug Wrench Handle 1
4	Hex Head Flange Bolt M5X 10 2
5	Square Nut M5 2
6	Key 2
7	Oil Fill Funnel (not pictured) 1

MAINTENANCE SAFETY

CAUTION

After any maintenance is performed, wash skin immediately using soap and clean water as exposure to lubricant may cause skin irritation.

WARNING

Personal safety is critical when attempting to service the generator. Improperly installed or adjusted components can make the generator unstable or dangerous. Improperly installed electrical components can cause engine or electrical systems failure. In either event, damage or serious injury could result. If you do not have the time, tools, and/or expertise necessary to complete a procedure properly, please see your Polaris dealer or other certified technician for service.

Failure to correct a problem before operation and improper maintenance can cause a malfunction resulting in injury or death. Always follow the inspection and maintenance schedules and requirements in this manual.

The following important safety precautions cannot warn of every possible hazard from maintenance. The decision to perform a given task must be evaluated by the individual performing it.

SAFETY PRECAUTIONS

Read the safety section of this manual.

Ensure the engine is off before performing any maintenance or repairs to minimize the potential for exposure to the following hazards:

• Fuel and fire - Avoid flames, sparks, and smoking during service.
• Carbon monoxide poisoning - Do not operate engine indoors. When operating outdoors, avoid open windows and doors.
• Burns - Allow the engine and exhaust system to cool before touching. Exercise caution when working around hazardous materials.
• Injury from moving parts - Avoid running the engine unless specifically instructed.

Follow the instructions and ensure the required tools are used.

Exercise caution when working around gasoline to reduce the possibility of fire or explosion. Use only non-flammable solvents to clean parts. Keep cigarettes, sparks, and flames away from all fuel-related components.

PERIODIC MAINTENANCE

Prior to performing any maintenance on your generator,

• Always stop the engine before servicing. Disconnect all devices and extension cords to avoid receiving an electrical shock.
• Periodic checks and maintenance are very important for keeping the generator in good condition.
• Inspect, clean, lubricate, adjust, and replace parts as necessary. When inspection reveals the need for replacement parts, use Polaris Genuine parts available from your Polaris dealer.
• Before beginning any maintenance procedure, read the instructions for the entire procedure. During some procedures, potentially hazardous products may be used. Always follow the instructions and warnings on the product packaging.

PERIODIC MAINTENANCE CHART

ITEM REMARKS PRE-	OPERATION CHECK (DAILY)	INITIAL 1 MONTH OR 20 HOURS	EVERY 3 MONTHS OR 50 HOURS	EVERY 6 MONTHS OR 100 HOURS	EVERY 12 MONTHS OR 300 HOURS
Spark Plug	Check condition. Adjust gap and clean. Replace as needed.			X
Spark Arrester	Clean the carbon deposits.			X
Engine Oil	Check the oil level.	X
	Replace oil.		X		X
Air Filter	Check filter.	X
	Clean. Replace as needed.			X_2
Fuel Sediment Cup	Clean.				X
Fuel Tank and Strainer	Clean.
Valve Clearance	Check and adjust when engine is cold.
Fuel Line	Check fuel line for twists, cracks, or damage. Replace as needed.	Every 2 years (Replace as necessary) _3
1. Log hours of operation to determine proper maintenance.2. Service more frequently when used in dusty conditions.3. These items should be serviced by an authorized Polaris dealer unless the owner has the tools and is mechanically proficient. Refer to the Polaris Service manuals.

FUEL SYSTEM

WARNING

Gasoline is highly flammable and explosive, and can cause serious injury or death. Stop the engine and keep heat, sparks, and flame away. Handle fuel only outdoors. Wipe up spills immediately.

FUEL LINE INSPECTION

Inspect the fuel line to ensure absence of twists, cracks, and / or damage. Replace as needed.

GAS TANK STRAINER

1. Remove the fuel tank cap.
2. Remove the fuel tank strainer from the fuel tank.
3. Remove any foreign objects or debris from the fuel tank strainer.
4. Inspect the fuel tank strainer for damage. Replace as needed.
5. Install the fuel tank strainer into the fuel tank.
6. Securely tighten the fuel tank cap.
7. Position the fuel valve switch OFF for storage or transport, or ON to run the generator.

ENGINE OIL

OIL RECOMMENDATION

Oil Recommendation POLARIS 5W-30 Generator Oil

Oil directly affects performance and service life. Use a 4-stroke automotive detergent oil, see page 87 for recommended oil. Other viscosities may be used when the applicable average temperature is within the recommended range.

The SAE oil viscosity and service category are in the API label on the oil container. Polaris recommends the use of API service category "SJ" or later, equivalent oil.

OIL LEVEL INSPECTION

CAUTION

Failure to use the proper 4-stroke engine oil may result in engine damage.

Using non-recommended oil may cause serious engine damage. Never substitute or mix oil brands.

Inspect the oil level before each use with the engine stopped and the genera on a level surface.

1. Remove the oil filler cap / dipstick and wipe it clean.
2. Insert the dipstick into filler neck, without screwing it in, to inspect the oil level.
3. Remove the dipstick and verify that the oil is at the upper limit. Add additional oil and inspect the level as needed until the upper limit has been reached.
4. Re-install the dipstick. Use a clean shop rag to clean any spilled oil.

NOTICE

• Do not tilt generator when adding engine oil. This could result in overfilling and damage to the engine.
• Use high quality 4-stroke engine oil, certified to meet or exceed API standard SG, SF, SAE ratings with strong detergents. Using non-detergent or 2-stroke oil could shorten the engine's working life.
• Do not mix different engine oils.
• Handle and store the engine oil with care, avoid getting dirt or dust into the engine oil.
• Before the engine oil falls below the safety margin, the low oil alert system automatically shut off the engine. The low oil light (RED) will illuminate.
• To avoid the inconvenience of unexpected engine shutdown, check oil before each use.

OIL CHANGE

WARNING

Oil may be hot. Do not allow hot oil to come into contact with skin, as serious burns may result.

NOTICE

Drain the oil while the engine is warm to assure rapid and complete draining.

IMPORTANT

Improper disposal of engine oil can be harmful to the environment and is unlawful. Properly dispose of used oil.

1. Start the engine and allow it to run for a few minutes. Stop the engine.
2. Position the fuel valve switch to OFF.
3. Remove the oil filler cap / dipstick.
4. Place a drain pan under the generator.
5. Remove the drain bolt and sealing washer and drain the oil.
6. Drain the used oil into a sealed container and take it to a recycling center. Not discard the oil in a trash can, dump it on the ground, or pour down the drain.
7. Re-install the oil drain bolt and sealing washer.
8. Place provided funnel into fill valve.
9. Fill oil to the high limit mark on the dipstick. Ensure that the oil level does n-rise past the threading of the cap.

MEASUREMENT

Oil Capacity

37.2 oz (1100.1 mL)

1. Remove funnel and re-install the dipstick.

2. Start the engine and let it run for 1 or 2 minutes. Stop the engine and look leaks.

3. Re-check the oil level on the dipstick and add oil as needed to bring the I to the upper mark on the dipstick.

4. Re-install the dipstick.
5. Wash hands with soap and water after handling used oil.

HIGH ALTITUDE JETS

WARNING

Gasoline is highly flammable and is explosive. You can be burned or seriously injured when handling fuel. Keep heat, sparks, and flame away. Wipe up spill immediately.

NOTICE

Using the wrong carburetor main jet may cause poor engine performance. If too lean of a main jet is used, severe engine damage may result.

ALTITUDE KITS

MODEL PART	NUMBER	DESCRIPTION
P2000i 2884865	K-HIGH,ALT,3-8K	P2000I
P3200iE 288486	6 K-HIGH,ALT,3-8K	P3200IE
P5500 / P6500	2884867 K-HIGH	ALT,3-8K,P5500/6500

ALTITUDE JET SPECIFICATIONS

MODEL ENGINE ALTITUDE JET MARK
P2000i 79cc		3000-6000 ft 68
		6000-8000 ft 67
P3200iE	208cc	3000-6000 ft 74
		6000-8000 ft 73
P5500	389cc	3000-6000 ft 103
		6000-8000 ft 101
P6500	420cc	3000-6000 ft 107
		6000-8000 ft 105

JET INSTALLATION

To change the carburetor main jet, follow this procedure:

1. Turn off the fuel supply.
2. Access the carburetor drain screw. Drain the fuel from the carburetor into a suitable container.
3. Remove the float bowl and chamber bolt.
4. Remove the electric solenoid valve.
5. Remove the main jet from the carburetor.
6. Install the correct main jet for the altitude in which the generator is operating. Do not over-tighten the jet.
7. Re-install the float bowl and chamber bolt.
8. Close carburetor drain screw.
9. Turn on fuel supply. Start generator and let engine run for several minutes.
10. Turn off generator. Verify there are no fuel leaks.

FUEL LINE

Inspect the fuel hose for cracks or damage. Replace as needed. See page 66 for more information about the fuel system.

AIR FILTER

WARNING

Do not use gasoline or low flash point solvents for cleaning. They are flammable and explosive under certain conditions.

NOTICE

An obstructed air filter restricts air flow to the carburetor. To prevent carburetor malfunction, regularly service the air filter. Service more frequently when operating the generator in extremely dusty areas.

1. Locate the air filter on the front of the generator beside the recoil assembly.
2. Unlatch the clips and remove the cover ①.
3. Remove the air filter.
4. If the filter is dirty or torn, replace it with a new one.
5. Reinstall the air filter cover.
6. Re-latch the clips securely.

Hand-drawn sketch of a yellow plastic door component mounted on a vehicle wheel (no text or symbols)

IMPORTANT

When replacing the filter, ensure that the filter is not pinched between the covers to secure a proper seal.

FOAM FILTERS

If using a foam air filter, follow the steps below to clean the filter before repla it in the air box.

1. Submerge the filter in a solution of warm water and household detergent.
2. Let the filter soak in the solution for a few minutes and then squeeze out excess water.
3. Repeat step 2 several times to ensure the water coming from the filter is clean. Then let the filter dry completely.
4. Once dry, pour air filter oil onto the filter and distribute evenly. Be sure to the filter of excess oil.

NOTICE

The use of air filter oil allows the filter to catch even the smallest particles of and dust.

1. If at any point during the cleaning process, the filter becomes damaged, the it must be replaced prior to operating your generator.

SPARK PLUG

SPARK PLUG INSPECTION

Using a non-recommended spark plug can result in serious engine damage. Always use recommended spark plugs. Refer to the Specification section for the recommended spark plug type. Always torque spark plugs to the specification.

In order to service the spark plug, the provided spark plug wrench is required.

CAUTION

A hot exhaust system and engine can cause burns. Wear protective gloves when removing a spark plug for inspection.

IMPORTANT

The spark plug must be free of deposits and properly gapped for proper engine operation. If the engine has been running, allow it to cool before servicing.

1. Remove the spark plug cap.
2. Clean any dirt from around the base of the spark plug.
3. Using the provided park plug wrench, remove the spark plug.
4. Inspect the electrode for wear and carbon buildup. Look for a sharp outer edge with no rounding or erosion of the electrode.

Technical line drawing of a mechanical assembly with pipes and components (no text or symbols)

1. Inspect spark plug. Replace if electrodes are worn or if insulator is cracked chipped, or fouled.
2. Clean the spark plug with a wire brush if it is to be reused.

NORMAL PLUG

The normal insulator tip is gray, tan or light brown. There will be few combustible deposits. The electrodes are not burned or eroded.

This indicates the proper type and heat range for the engine and the service.

WET FOULED PLUG

The wet fouled insulator tip is black. A damp oil film covers the firing end. Th may be a carbon layer over the entire nose. Generally, the electrodes are not worn. Fouling may be caused by excessive oil or by frequent short trips, especially in cold weather.

SPARK PLUG REPLACEMENT

IMPORTANT

Prior to replacing the spark plug, complete the inspection steps outlined on page 73.

1. Remove the spark plug cap.
2. Clean any dirt from around the base of the spark plug.
3. Using the provided park plug wrench, remove the spark plug.
4. Using a wire-type feeler gauge, measure the spark plug electrode gap. If necessary, correct the gap by carefully bending the side electrode.

MEASUREMENT

Spark Plug Gap 0.028-0.031 in (0.7-0.8 mm)

1. Ensure the spark plug sealing washer is in good condition and thread the spark plug in by hand to prevent cross-threading.

2. After a new spark plug has been seated by hand, it should be tightened 1/2 turn with a wrench to compress the sealing washer. If a used plug is being reinstalled, it should only require 1/8 to 1/4 turn after being seated.

3. Re-install the spark plug cap.

NOTICE

A loose spark plug can overheat and damage the engine. Over tightening the spark plug can damage the plug threads.

Never use a spark plug with an improper heat range.

SPARK ARRESTER

The spark arrester is located on the end of the muffler.

WARNING

Generator exhaust system gets hot enough to ignite some materials and burn skin if touched.

Allow generator and exhaust to cool before performing spark arrestor maintenance.

CAUTION

The spark arrester must be serviced every 100 hours to maintain its efficiency.

Before performing any inspection or maintenance on the battery, ignition switch should be positioned to OFF.

1. Remove screw① holding the spark arrester to the muffler
2. Pull the end cap off to remove the arrester screen.
3. Clean the spark arrestor with a stiff wire brush.
4. Replace if the wire mesh is perforated or torn.
5. Reinstall screen and cap. Secure cap to the muffler with the screw.

3D rendering of a cylindrical mechanical component with a meshed inner surface and labeled part 1 (no text or symbols beyond label)

Technical line drawing of a tractor's wheel assembly and chassis (no text or symbols)

BATTERY

WARNING

Always disconnect the negative (black) cable first when removing the battery. Always connect the negative (black) cable last during installation. Failure to properly connect/disconnect battery cables may result in an explosion and cause serious injury or death.

Battery electrolyte contains sulfuric acid which is poisonous and can cause serious burns. Avoid contact with eyes, skin, and clothing. Ensure proper protective gloves, goggles, and clothing are worn. If eyes are exposed, flush with water for 15 minutes and seek medical attention. If external contact, flus with water. If ingested, drink large quantities of water or milk. Follow with mi of magnesia, beaten egg, or vegetable oil. Seek immediate attention.

Overheating of battery may cause an explosion, and severe injury or death. Stop charging if the battery becomes very warm to the touch. Allow battery completely cool before resuming charging.

IMPORTANT

Always keep battery terminals and connections free of corrosion. Avoid spilling of electrolyte. Damage to equipment may result.

Immediately wash off any electrolyte spills with a solution of one tablespoon baking soda and one cup water. If cleaning is necessary, remove corrosion with a stiff wire brush. Wash with a solution of one tablespoon baking soda and cup water. Rinse well with tap water and dry off with clean shop towels. Co the terminals with dielectric grease or petroleum jelly.

BATTERY REMOVAL

1. Access the battery ^① from below the control panel.
2. Disconnect the black (negative) battery cable first by removing the M5 screw.

3. Disconnect the red (positive) battery cable last by removing the M5 screw.

4. Disconnect the battery hold-down strap.

5. Lift the battery out of the generator.

Diagram of a vehicle chassis with wheels and a yellow battery block, no text or symbols present

BATTERY INSTALLATION

Using a new battery that has not been fully charged can damage the battery and result in a shorter life. It can also hinder generator performance. Follow the instructions in the Battery Charging section before installing the battery.

1. Ensure that the battery is fully charged.
2. Place the battery in the battery holder.
3. Coat the terminals with dielectric grease or petroleum jelly.
4. Secure the battery hold-down strap.
5. Connect and tighten the red (positive) cable first.

6. Connect and tighten the black (negative) cable last.

7. Verify that cables are properly routed. Cables should be safely tucked away at the front and rear of the battery.

BATTERY MAINTENANCE AND CHARGING

WARNING

An overheated battery may explode, causing severe injury or death. Always watch charging times carefully. Stop charging if the battery becomes very warm to the touch. Allow it to cool before resuming charging.

The sealed battery is already filled with electrolyte and has been sealed and fully charged at the factory. Never pry the sealing strip off or add any other fluid to this battery.

The single most important thing about maintaining a sealed battery is to keep fully charged. Check the battery voltage with a voltmeter or multimeter. A fully charged battery will register 12.8 V or higher. If the voltage falls below 12.5V, charge it immediately, or the battery runs the risk of sulfation and reduced battery life.

If you do not use the generator for more than TWO WEEKS, Polaris recommends maintaining the battery through the use of a trickle charger. During charging, place the charger outside of the generator and protect it from moisture.

BATTERY STORAGE

If you plan to store the generator for ONE MONTH or longer, remove the bat from the generator, then store the battery in a cool and dry location. Continue maintain the battery with a trickle charge.

When using an automatic charger, refer to the charger manufacturer's instructions for recharging. and by following the guidelines below. Always verify battery condition before and 1-2 hours after charge completion.

State of Charge Voltage (DC)		Action	Charge Time*
100% 12.8-13.0 volts None, check monthly			None required
75%-100% 12.6-12.8 volts May need slight charge, if no charge given, check in 2 weeks			3-6 hours
50%-75% 12.3-12.6 volts Needs		charge 5-11 hours
25%-50% 12.0-12.3 volts Needs		charge At least 13 hours
0%-25% 12.0 volts or less Needds charge At least 20 hours
* Using AGM specific charger at standard amps specified on top of battery

CLEANING AND STORAGE

CLEANING THE GENERATOR

WARNING

Never pour water directly onto the generator or wash it with water. Contact water could result in severe shock or electrocution. Keep generator dry and away from all sources of moisture.

To clean the generator, wipe down with a dry shop rag. Always use clean clo and pads for cleaning and polishing.

If an informational or graphic label becomes illegible or comes off, contact your POLARIS dealer to procure a replacement. Replacement safety labels are provided by POLARIS at no charge.

STORAGE PREPARATION

WARNING

Gasoline is highly flammable and explosive and can cause serious injury. Stop the engine and keep heat, sparks, and flame away. Only handle fuel outdoors. Wipe up spills immediately.

Long-term storage of the generator will require some additional preventative measures to guard against deterioration. If fuel is kept in the generator, run the engine for at least 30 minutes each month to ensure an easy start during the next operation. Be sure the storage area is free of excessive humidity and dust.

1. If the generator will be stored with fuel, add fuel stabilizer. See page 79.
2. If the generator will be stored dry of fuel, drain all fuel and fog the engine prior to storage. See page 79 and page 81.
3. Change engine oil. See page 68.
4. Remove battery and store in cool, dry location. Use a battery trickle charger to maintain battery charge.
5. Clean exterior of the generator with a clean, dry cloth.

WARNING

Do not pour water directly on to the generator or wash it with water.

1. Turn fuel valve switch to OFF.

ACCESSING THE FUEL TANK

1. Remove the fuel tank cap.
2. Remove debris as needed.
3. When maintenance is complete, re-install the fuel tank strainer into the fuel tank.
4. Securely tighten the fuel tank cap.

Hand-drawn sketch of a yellow macarack on a circular plate with a numbered label (1), no text or symbols present.

STABILIZING THE FUEL

WARNING

A hot engine or exhaust system can cause severe burns and ignite flammable material. Ensure adequate time for cooling before storage or transportation.

This procedure applies if keeping gasoline in fuel tank during storage. Drain the carburetor bowl prior to any storage period longer than 30 days. See page 95 suitable fuel stabilizer.

1. Access the fuel tank.
2. Add a suitable fuel stabilizer.

DRAINING THE FUEL

WARNING

Gasoline is highly flammable and explosive and can cause serious injury or death. Stop the engine and keep heat, sparks, and flame away. Handle fuel only outdoors. Wipe up spills immediately. Do not spill fuel when draining the fuel tank. Spilled fuel is a fire hazard, causes environmental damage, and can cause damage to paint and plastic. Wipe up spills immediately.

Perform this procedure if fuel will NOT be kept in the fuel tank during storage before transportation.

GAS TANK

1. Access the fuel tank and remove the gas ① cap

2. Empty fuel tank into an approved gasoline container. Polaris recommends using a commercially available gasoline hand pump to empty the tank. Do not use an electric pump.

3. Re-install gas cap onto the tank and securely tighten.

Technical line drawing of a vehicle chassis frame with a highlighted yellow oval component (no text or symbols)

FUEL VALVE

1. Access the fuel drain valve behind the control panel.
2. Turn fuel valve switch to ON and then remove the fuel valve drain screw
3. Drain the gasoline from the valve and into a suitable container.

Technical diagram of a mechanical assembly with yellow components and a green downward arrow indicating a process (no text or symbols present)

CARBURETOR

1. Access the carburetor behind the air box near the front of the generator.

2. Remove the carburetor drain screw.

3. Drain the gasoline from the carburetor into a suitable container.

4. Re-install drain screw.

Technical illustration of a mechanical assembly with a blue component and pipe, no visible text or symbols

FOGGING THE ENGINE

1. Turn the ignition key to the OFF position.
2. Remove the spark plug cap.
3. Using the provided park plug wrench, remove the spark plug.
4. Spray Polaris fogging oil into the cylinder. Crank the engine several revolutions to distribute the oil and then reinstall the spark plug.
5. Ensure that the spark plug sealing washer is in good condition and hand-tighten the spark plug to prevent cross-threading.
6. Using a spark plug wrench, carefully tighten the spark plug. Torque the spa plug to specification, see page 72.
7. Slowly pull the starter grip until resistance is felt. At this point, the piston is coming up on its compression stroke and both the intake and exhaust valve are closed. Storing the engine in this position will help protect it from internal corrosion.
8. Re-install the spark plug cap.
9. Cover the generator and store indoors, in a dry, well-ventilated area.

Technical line drawing of a mechanical assembly with no visible text or symbols

Polaris Fogging Oil

(12 oz aerosol can)

Part Number: 2870791

BATTERY STORAGE

Recharge the battery once a month or use a trickle charger to maintain battery charge. See page 82 for additional instruction.

STORAGE PRECAUTIONS

NOTICE

Do not store the generator outdoors in the cold weather when not in use.

• Select a well-ventilated storage area away from any flame-operated appliance (i.e., furnace, water heater, or clothes dryer). Avoid areas containing a spark-producing electric motor, or where power tools are operated.
• Be sure storage area is free of excessive humidity and dust.
• Place generator on a level surface. Tilting can cause fuel or oil leakage.
• With the engine and exhaust system cooled, cover the generator to prevent dust contamination. Do not use a plastic sheet as a dust cover. Nonporous covers trap moisture around the generator, promoting rust and corrosion.
• Position fuel tank cap vent lever to OFF to reduce leakage possibilities.

REMOVAL FROM STORAGE

NOTICE

If the cylinder was coated with oil during storage preparation, the engine may smoke briefly at startup. This is normal.

1. Re-install battery. See page 76.
2. Perform all steps in the Pre-Operation Inspection. See page 44.
3. If fuel was drained during storage preparation, fill tank with fresh gasoline. See page 45. If gasoline is stored in a container, ensure the gasoline is fresh. Gasoline oxidizes and deteriorates over time, causing hard starting.

TRANSPORTING THE GENERATOR

WARNING

Transporting the generator with gasoline in the fuel tank is prohibited. Transporting the generator with fuel in the tank could result in severe generat damage as well as serious injury or death. Be sure the fuel tank cap is tig and the generator is sitting upright during transportation.

WARNING

A hot engine or exhaust system can cause severe burns and ignite flammable material. Ensure adequate time for cooling before storage or transportation.

IMPORTANT

Take care not to drop or strike the generator when transporting. Do not place heavy objects on the generator. When transporting, firmly secure the generator to the transport vehicle.

1. If the generator has been used, allow it to cool for at least 15 minutes before loading it on the transport vehicle.
2. Drain the fuel from tank and carburetor. See page 79.
3. Position the ignition switch① to OFF.
4. Position the fuel valve switch to OFF.
5. Keep generator level and upright during transport.

Technical diagram showing labeled components of a mechanical part, including a cylindrical component with internal structure and two circular views with numbered annotations.

SPECIFICATIONS

P5500 / P6500

SPECIFICATIONS
ALTERNATOR
Model P5500 P6500
AC Output Voltage 120V / 240V
DC Output Voltage 12V (5.0A)
Rated Output 5000 W 6000 W
Maximum Output 5500 W 6500 W
Frequency 60 Hz
Type Open Frame
ENGINE
Type 4-stroke, OHV Air-cooled, Single Cylinder
Displacement 389 cm3 (23.7 cu in) 420cm3 (25.6 cu in)
Engine Speed	3600 rpm
Cooling System	Forced Air
Ignition System	Transistorized
Engine Oil	Polaris 5W-30 Generator Oil
Engine Oil Capacity	37.2 fl oz (1100.1 mL)
Intake Valve Clearance-Cold	See service manual
Exhaust Valve Clearance-Cold	See service manual
Spark Plug Gap	WR7DC .024 - .028in. (0.6 - 0.7mm)
GENERATOR
Fuel	87 Octane (Up to 10% Oxygenated)
Fuel Tank Capacity	6.6 gallons (25 L)
Noise Level dB(A) range*	75 - 78 dB(A) *dB(A) measured outdoors at 23 feet (7 meters) from control panel side
Starting System	Electric with recoil backup
Dimensions (L x W x H)	31.9 in (810.3 mm)24 in (609.6 mm)25.4 in (645.2 mm)	31.9 in (810.3 mm)24 in (609.6 mm)25.4 in (645.2 mm)
Weight 205 lbs (93 kg) 215 lbs (98 kg)
Full Tank Run Time Hours Rated Load	5 hrs 5 hrs
AC/DC Simultaneously Usage	Yes
Parallel Function No

POLARIS PRODUCTS

OIL AND LUBRICANTS

POLARIS PRODUCTS
PART NUMBER DESCRIPTION
ENGINE OIL
2879383 Polaris 5W-30	Generator Oil (1 Quart) (32 oz.)
ADDITIVES
2881413 Premium Carbon Clean / Fuel Stabilizer (12 oz.) (12 count)
2870791 Polaris Fogging Oil (12 oz. Aerosol Can)

TROUBLESHOOTING

ENGINE WILL NOT TURN OVER

POSSIBLE CAUSE SOLUTION
Starter recoil damage Take the generator to	an authorized Polaris servicing dealer or refer to the service manual
Low battery voltage Recharge the battery to	12.8V DC.
Starter motor damaged Take the generator to	an authorized Polaris servicing dealer or refer to the service manual
Internal engine damage Take the generator to	an authorized Polaris servicing dealer or refer to the service manual

ENGINE TURNS OVER, BUT WILL NOT START

POSSIBLE CAUSE SOLUTION
Engine is flooded Wait 15 minutes before restarting. Use recoil.
Out of fuel Refuel.
Low Oil Repeat Pre-operation Inspection.
Water is present in fuel Drain fuel system and refuel.
Old or non-recommended fuel Drain fuel system and refuel.
Fouled or defective spark plug	Inspect spark plug and replace, if needed.
No spark to spark plug	Inspect spark plug. Verify engine switch is ON.
Water or fuel in crankcase	Take the generator to an authorized Polaris servicing dealer or refer to service manual.
Low battery voltage	Recharge the battery to 12.8V DC.
Mechanical failure	Take the generator to an authorized Polaris servicing dealer or refer to service manual.
Fuel valve is OFF	Turn fuel valve ON.

ENGINE LACKS POWER

POSSIBLE CAUSE SOLUTION
Air filter restricted Clean or replace air filter.
Bad fuel; generator stored without treating or draining gasoline, or refueled with bad gasoline	Drain the fuel system and refuel.
Mechanical failure Take the generator to an authorized Polaris servicing dealer or refer to the service manua

ENGINE BACKFIRES

POSSIBLE CAUSES SOLUTION
Weak spark from spark plug Inspect, clean, and / or replace spark plug.
Incorrect spark plug gap or heat range Set gap to specification or replace spark plug.
Old or non-recommended fuel Drain the fuel system and refuel.
Incorrectly installed spark plug wires Take the generator to an authorized Polaris servicing dealer or refer to the service manual
Incorrect ignition timing Take the generator to an authorized Polaris servicing dealer or refer to the service manual
Mechanical failure Take the generator to an authorized Polaris servicing dealer or refer to the service manual
Loose ignition connections Check all connections and tighten.
Water present in fuel Drain the fuel system and refuel.

ENGINE PINGS OR KNOCKS

POSSIBLE CAUSE SOLUTION
Poor quality or low octane fuel Drain the fue	system and refuel.
Incorrect ignition timing Take the generator to	an authorized Polaris servicing dealer or refer to the service manua
Incorrect spark plug gap or heat range Set gap	gap to specification or replace spark plugs.

ENGINE RUNS IRREGULARLY, STALLS OR MISFIRES

POSSIBLE CAUSE SOLUTIONS
Fouled or defective spark plug Inspect, clean,	and / or replace spark plug.
Worn or defective spark plug Take the generator to an authorized Polaris servicing dealer or refer to the service manual
Incorrect spark plug gap or heat range Set gap to specification or replace spark plug.
Loose ignition connections Check all connections and tighten.
Water present in fuel Drain the fuel system and refuel.
Low battery voltage Recharge battery to 12.8 Vdc.
Kinked or plugged fuel tank vent line Inspect and replace.
Incorrect fuel Drain the fuel system and refuel.
Economy throttle control malfunction Take the generator to an authorized Polaris servicing dealer or refer to the service manual
Other mechanical failure	Take the generator to an authorized Polaris servicing dealer or refer to the service manual

LEAN FUEL

POSSIBLE LEAN FUEL CAUSE	SOLUTION
Low or contaminated fuel	Add fuel, or drain fuel system and refuel.
Kinked or plugged fuel tank vent	Inspect and replace.
Low octane fuel	Drain fuel system and refuel.
Carburetor jetting incorrectly	Take generator to an authorized Polaris servicing dealer or refer to service manual.

RICH FUEL

POSSIBLE RICH FUEL CAUSE	SOLUTION
Incorrect fuel Drain fuel system and refuel.
Stopping / starting without adequate warm-up	Allow engine to warm up before operating and / or stopping.
Incorrect spark plug	Inspect and replace with correct plug.
Clogged air filter	Inspect and clean or replace.

ENGINE STOPS OR LOSES POWER

POSSIBLE CAUSE SOLUTION
Out of fuel Refuel.
Fouled, worn, incorrect, or defective spark plug;Inspect, clean, and / or replace the spark plug / incorrect spark plug gap or heat range set the spark plug gap to specification.
Loose ignition connections Check all connections and tighten.
Water present in fuel / incorrect fuel Drain the fuel system and refuel.
Kinked or plugged fuel tank vent line Inspect and replace.
Economy throttle control malfunction Take the generator to an authorized Polaris servicing dealer or refer to the service manual.
No / low oil in the engine Check / replace oil.
Clogged air filter Clean or replace the air filter.
Mechanical failure Take the generator to an authorized Polaris servicing dealer or refer to the service manual.

NO POWER ATAC RECEPTACLES

POSSIBLE CAUSE SOLUTION
Output indicator is OFF, and overload indicator is ON	Take the generator to a Polaris servicing dealer or refer to the service manual.
AC circuit protector tripped Check AC load and reset circuit protector.
Overload protector tripped	Push the Overload Restart switch.
Faulty power tool or appliance	Replace or repair power tool or appliance; stop and restart the engine.
Faulty generator Take the generator to an authorized Polaris servicing dealer or refer to the service manual.

NO POWER AT DC RECEPTACLES

POSSIBLE CAUSE SOLUTION
Blown fuse	Replace the fuse.
Faulty generator Take the generator to an authorized Polaris servicing dealer or refer to the service manual

WARRANTY

LIMITED WARRANTY

POLARIS Sales Inc., 2100 Highway 55, Medina, MN 55340 gives a THREE YEAR LIMITED WARRANTY for consumer use and a ONE YEAR LIMITED WARRANTY for commercial use on all components of your POLARIS generator against defects in material or workmanship. This warranty covers parts and labor charges for repair or replacement of defective parts and begins on the date of purchase.

This warranty is transferable to another owner during the warranty period through a POLARIS dealer, but any such transfer will not extend the original term of the warranty.

REGISTRATION

The Warranty Registration Form must be completed by the purchaser and submitted to POLARIS within ten days of purchase. Upon receipt of this registration, POLARIS will record the registration information for warranty. No verification of registration will be sent to the purchaser. Registration cards can be found in the original box of the product and can be mailed into POLARIS the address listed on the card, or completed at www.polarispower.com/warranty. NO WARRANTY COVERAGE WILL BE ALLOWED UNLESS YOUR GENERATOR IS REGISTERED WITH POLARIS.

WARRANTY COVERAGE AND EXCLUSIONS LIMITATION OF WARRANTIES AND REMEDIES

This POLARIS limited warranty excludes any failures that are not caused by a defect in material or workmanship. This warranty does not cover claims of defective design. This warranty also does not cover accidental damage, normal wear and tear, abuse or improper handling. This warranty also does not cover any unit that has been altered structurally, modified, neglected, improperly maintained, or used for purposes other than for which it was designed.

This warranty excludes damages or failures resulting from improper lubrication; improper engine timing; improper fuel; surface imperfections caused by external stress, heat, cold or contamination; operator error or abuse; improper component alignment, tension, adjustment or altitude compensation; failure due to snow, water, dirt or other foreign substance ingestion/contamination; improper maintenance; modified components; use of aftermarket components resulting in failure; unauthorized repairs; repairs made after the warranty period expires or by an unauthorized repair center. This warranty will not apply to any product which has been damaged by abuse, accident, fire, or any other casualty not determined to be a defect or materials or workmanship.

LUBRICANTS AND FLUIDS

1. Mixing oil brands or using non-recommended oil may cause engine damage. We recommend the use of POLARIS engine oil.
2. Damage or failure resulting from the use of non-recommended lubricants or fluids is not covered by this warranty.

Some items are considered “consumable” meaning they are considered part of normal maintenance or part of completing an effective repair. The following items are excluded from warranty coverage in the event of a warranty claim: spark plugs, filters, sealants, and lubricants.

This warranty does not allow for coverage of personal loss and provides no coverage for mileage, transportation costs, shipping or handling fees, product pick-up or delivery, replacement rentals, loss of product use or profits, or loss vacation or personal time.

THE EXCLUSIVE REMEDY FOR BREACH OF THIS WARRANTY SHALL BE, AT POLARIS' OPTION, REPAIR OR REPLACEMENT OF ANY DEFECTIVE MATERIALS, COMPONENTS, OR PRODUCTS. THE REMEDIES SET FORTH IN THIS WARRANTY ARE THE ONLY REMEDIES AVAILABLE TO ANY PERSON FOR BREACH OF THIS WARRANTY. POLARIS SHALL HAVE NO LIABILITY TO ANY PERSON FOR INCIDENTAL, CONSEQUENTIAL OR SPECIAL DAMAGES OF ANY DESCRIPTION, WHETHER ARISING OUT OF EXPRESS OR IMPLIED WARRANTY OR ANY OTHER CONTRACT, NEGLIGENCE, OR OTHER TORT OR OTHERWISE. THIS EXCLUSION OF CONSEQUENTIAL, INCIDENTAL, AND SPECIAL DAMAGES IS INDEPENDENT FROM AND SHALL SURVIVE ANY FINDING THAT THE EXCLUSIVE REMEDY FAILED OF ITS ESSENTIAL PURPOSE.

THE IMPLIED WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE IS EXCLUDED FROM THIS LIMITED WARRANTY. ALL OTHER IMPLIED WARRANTIES (INCLUDING BUT NOT LIMITED TO THE IMPLIED WARRANTY OF MERCHANTABILITY) ARE LIMITED IN DURATION TO THE ABOVE SIX MONTH WARRANTY PERIOD. POLARIS DISCLAIMS ALL EXPRESS WARRANTIES NOT STATED IN THIS WARRANTY. SOME STATES DO NOT PERMIT THE EXCLUSION OR LIMITATION OF INCIDENTAL OR CONSEQUENTIAL DAMAGES OR ALLOW LIMITATIONS ON THE DURATION OF IMPLIED WARRANTIES, SO THE ABOVE LIMITATIONS MAY NOT APPLY TO YOU IF INCONSISTENT WITH CONTROLLING STATE LAW.

HOW TO OBTAIN WARRANTY SERVICE

If your generator requires warranty service, you must take it to a POLARIS Servicing Dealer. When requesting warranty service you must present your cop of the Warranty Registration from the dealer. (THE COST OF TRANSPORTATION TO AND FROM THE DEALER IS YOUR RESPONSIBILITY). POLARIS suggests that you use your original selling dealer; however, you may use any POLARIS Servicing Dealer to perform warranty service.

IN THE COUNTRY WHERE YOUR PRODUCT WAS PURCHASED:

Warranty or Service Bulletin repairs must be done by an authorized POLARIS dealer, or other qualified person. If you move or are traveling within the country where your product was purchased, Warranty and Service Bulletin repairs may be requested from any authorized POLARIS dealer, or other qualified person, that sells the same line as your product.

OUTSIDE THE COUNTRY WHERE YOUR PRODUCT WAS PURCHASED:

If you are traveling temporarily outside the country where your product was purchased, you should take your product to an authorized POLARIS dealer, or other qualified person. You must show the dealer photo identification from the country of the selling dealer's authorized location as proof of residence. Upon residence verification, the servicing dealer will be authorized to perform the warranty repair.

IF YOU MOVE:

If you move to another country, be sure to contact POLARIS Customer Assistance and the customs department of the destination country before you move. Product importation rules vary considerably from country to country. You may be required to present documentation of your move to POLARIS in order to continue your warranty coverage. You may also be required to obtain documentation from POLARIS in order to register your product in your new country. You should warranty register your product at a local POLARIS dealer in your new country immediately after you move to continue your warranty coverage and to ensure that you receive information and notices regarding your product.

IF YOU PURCHASE FROM A PRIVATE PARTY:

If you purchase a POLARIS product from a private party, to be kept and used outside of the country in which the product was originally purchased, all warranty coverage will be denied. You must nonetheless register your product under your name and address with a local POLARIS dealer in your country to ensure that you receive safety information and notices regarding your product.

EXPORTED PRODUCTS

EXCEPT WHERE SPECIFICALLY REQUIRED BY LAW, THERE IS NO WARRANTY OR SERVICE BULLETIN COVERAGE ON THIS PRODUCT IF IT IS SOLD OUTSIDE THE COUNTRY OF THE SELLING DEALER'S AUTHORIZED LOCATION. This policy does not apply to products that have received authorization for export from POLARIS. Dealers may not give authorization for export. You should consult an authorized dealer to determine this product's warranty or service coverage if you have any questions. This policy does not apply to products registered to government officials or military personnel on assignment outside the country of the selling dealer's authorized location. This policy does not apply to Safety Bulletins.

NOTICE

If your product is registered outside of the country where it was purchased an you have not followed the procedure set above, your product will no longer be eligible for warranty or service bulletin coverage of any kind, other than safety bulletins. Products registered to government officials or military personnel on assignment outside of the country where the product was purchased will continue to be covered by the Limited Warranty.

Please work with your dealer to resolve any warranty issues. Dealership contacts can be found via this website, if needed:

www.polaris.com/en-us/contact

Should your dealer require any additional assistance, they will contact the appropriate person at POLARIS.

This warranty gives you specific legal rights, and you may also have other right which vary from state to state or in different countries. If any of the above ten are void because of federal, state, local law, all other warranty terms will remain in effect.

For questions call POLARIS Customer Assistance:

United States & Canada: 1-800-POLARIS (1-800-765-2747)

French: 1-800-268-6334

EMISSION CONTROL SYSTEM LIMITED WARRANTY

This emissions limited warranty is in addition to the POLARIS standard limited warranty for your product.

YOUR WARRANTY RIGHTS AND OBLIGATIONS UNITED STATES & CANADA

POLARIS must warrant the emission control system on your generator for the periods of time listed in the Warranty Coverage section below provided there has been no abuse, neglect or improper maintenance of your small off-road engine. POLARIS Industries Inc. warrants that at the time it is first purchased, this emissions-certified product is designed, built and equipped to conform with the requirements of the U.S. Environmental Protection Agency and the Environment and Climate Change Canada regulations. POLARIS warrants that the product is free from defects in materials or workmanship that would cause it to fail to meet these regulations. Where a warrantable condition exists, POLARIS will repair your generator engine at no cost to you including diagnosis, parts and labor.

Your emission control system may include parts such as the carburetor or fuel-injection system, the ignition system, and catalytic converter. Also included may be hoses, belts, connectors and other emission-related assemblies. Additional covered parts are listed in the Warranty Coverage section below.

CALIFORNIA RESIDENTS

The California Air Resources Board and POLARIS are pleased to explain the emission control system's warranty on your model year 2020 and later generator engine. In California, new small off-road engines must be designed, built, and equipped to meet the State's stringent anti-smog standards. POLARIS Industries Inc. warrants that at the time it is first purchased, this emissions-certified product is designed, built, and equipped so as to conform with all applicable regulations adopted by the Air Resources Board pursuant to its authority in Chapters 1 and 2, Part 5, Division 26 of the Health and Safety Code. POLARIS warrants that the engine is free from defects in materials and workmanship that cause the failure of a warranted part to be identical in all material respects to the part as described in the engine manufacturer's application for certification for a minimum period of time as listed in the Warranty Coverage section below.

OWNER'S WARRANTY RESPONSIBILITIES

As the generator engine owner, you are responsible for performance of the required maintenance listed in your owner's manual. POLARIS recommends that you retain all receipts covering maintenance on your generator engine, but POLARIS cannot deny warranty coverage solely for the lack of receipts or for your failure to ensure the performance of all scheduled maintenance.

As the generator engine owner, you should be aware that POLARIS may deny you warranty coverage if your engine or a part has failed due to abuse, neglect or improper maintenance or unapproved modifications.

You are responsible for presenting your generator engine to a POLARIS dealer or service center as soon as the problem exists. The warranty repairs shall be completed in a reasonable amount of time, not to exceed 30 days.

WARRANTY COVERAGE

The warranty period for this emission-certified product sold in the United States and Canada starts on the date the equipment is delivered to the original retail purchaser and continues for a period of 24 calendar months. This warranty is transferable to each subsequent purchaser for the duration of the warranty period.

This emissions limited warranty covers components whose failure increases emissions, and it covers components of systems whose only purpose is to control emissions. Repairing or replacing other components not covered by this warranty is the responsibility of the product owner. This emissions limited warranty does not cover components whose failure does not increase the product's regulated emissions.

For exhaust emissions, emission-related components include any engine parts related to the following systems:

• Air-induction system
- Fuel system
- Ignition system
- Exhaust gas recirculation system

The following parts are also considered emission-related components for exhaust emissions:

• Aftertreatment devices
- Crankcase ventilation valves
- Sensors
• Electronic control units

The following parts are considered emission-related components for evaporation emissions:

• Fuel Tank
• Fuel Cap
• Fuel Line
• Fuel Line Fittings
• Clamps*
• Pressure Relief Valves*
• Control Valves*
  • Control Solenoids*
  • Electronic Controls*
  • Vacuum Control Diaphragms*
• Control Cables*
• Control Linkages*
• Purge Valves
• Vapor Hoses
• Liquid/Vapor Separator
• Carbon Canister
• Canister Mounting Brackets
  • Carburetor Purge Port Connector

*As related to the evaporative emission control system

Emission-related components also include any other part whose only purpose is to reduce emissions or whose failure will increase emissions without significantly degrading engine/equipment performance.

If any emissions related component on your engine is defective, POLARIS will repair or replace the defective component without any charge for diagnosis, parts, or labor. All defective parts replaced under this warranty become the property of POLARIS.

EXCLUSIONS

This limited warranty excludes failures not caused by a defect in material or workmanship. This limited warranty does not cover damage due to accidents, abuse or improper handling, maintenance or use. This limited warranty also does not cover any engine that has been structurally altered. This limited warranty also does not cover physical damage, corrosion or defects caused by fire, explosions or other similar causes beyond the control of POLARIS. Owners are responsible for performing the scheduled maintenance identified in the owner's manual. POLARIS may deny warranty claims for failures that have been caused by the owner's or operator's improper maintenance or use, by accidents for which POLARIS has no responsibility, or by acts of God.

TO OBTAIN WARRANTY SERVICE

The generator engine owner must, at their own expense, take the small off-road engine, or the product on which it is installed, along with the sales registration card or other proof of original purchase date, to any qualified repair shop or qualified person. Any qualified repair shop or person may maintain, replace, or repair the emission control devices or systems on your product. An authorized POLARIS dealer can perform any service that may be necessary for your product. POLARIS also recommends POLARIS parts, however equivalent parts may be used for such service. It is a potential violation of the Clean Air act if a part supplied by an aftermarket parts manufacturer reduces the effectiveness of the product's emission controls. Tampering with emission controls is prohibited by federal law.

DISCLAIMER

The exclusive remedy for breach of this limited warranty shall be, at the exclusive option of POLARIS, repair or replacement of any defective materials, components or products. THE REMEDIES SET FORTH IN THIS LIMITED WARRANTY ARE THE ONLY REMEDIES AVAILABLE TO ANY PERSON FOR BREACH OF THIS WARRANTY. POLARIS SHALL HAVE NO LIABILITY TO ANY PERSON FOR INCIDENTAL, CONSEQUENTIAL OR SPECIAL DAMAGES OF ANY DESCRIPTION, WHETHER ARISING OUT OF EXPRESS OR IMPLIED WARRANTY OR ANY OTHER CONTRACT, NEGLIGENCE OR OTHER TORT OR OTHERWISE. THIS EXCLUSION OF CONSEQUENTIAL, INCIDENTAL, AND SPECIAL DAMAGES IS INDEPENDENT FROM AND SHALL SURVIVE ANY FINDING THAT THE EXCLUSIVE REMEDY FAILED OF ITS ESSENTIAL PURPOSE.

ALL IMPLIED WARRANTIES (INCLUDING BUT NOT LIMITED TO ANY IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE) ARE LIMITED IN DURATION TO THE WARRANTY PERIOD DESCRIBED HEREIN. POLARIS DISCLAIMS ALL EXPRESS

WARRANTIES NOT STATED IN THIS WARRANTY. Some states do not allow limitations on how long an implied warranty lasts, so the above limitation may not apply if it is inconsistent with the controlling state law.

SPARK ARRESTOR LIMITED WARRANTY

POLARIS warrants that the spark arrestor in this product will meet the efficiency requirements of USFS standard 5100-1C for at least 1000 hours when subjected to normal use and when maintenance and installation are in accordance with POLARIS recommendations.

CONTACT INFORMATION

If you have any questions regarding your warranty rights and responsibilities, please contact POLARIS Customer Assistance at 1-800-POLARIS (1-800-765-2747). If your questions regard the emissions warranty in California, you may also contact the California Air Resources Board at 9528 Telstar Avenue, El Monte, CA 91731.

United States & Canada: 1-800-POLARIS (1-800-765-2747)

French: 1-800-268-6334

MAINTENANCE LOG

MAINTENANCE LOG

Use the following chart to record periodic maintenance.

DATE	HOURS	TECH	NICIAN SERVICE	PERFORMED / COMMENTS

120V AC Twist Lock Receptacle.... 33

A

AC Operation.... 49

AC Receptacles 33

Adding Fuel.... 43

Air Conditioning Operation...... 55

Air Filter.... 70

Alterations 59

Assembly

Importance.... 35

Lift Mount...... 40

Wheel Locks.... 38

Wheels.... 37

B

Battery 75

Charging 76

Installation 76

Maintenance 76

Removal.... 76

Storage 82

BatteryMINDer® 76

C

Carbon Monoxide 13

Carbon Monoxide Warning 26

Carburetor Modification.... 58

Choke Lever.... 31

Circuit Breaker 32

Circuit Protectors.... 32

Cleaning.... 77

Connection to Building

Electrical System 55

Control Panel.... 29

D

DC Operation 53

Battery Charging 53

DC Receptacle.... 33

E

Ear Protection.... 23

Emission Control System Limited Warranty.... 98

Engine Oil.... 41

Exported Products 97

Exposure to Exhaust 17

Extension Cord 16

F

Failure to Inspect Before

Operating 13

Features and Controls 27

Fire Safety 17

Fogging the Engine.... 81

Fuel

Drain Fuel.... 79

Fuel System 66

Fuel Tank

Access 78

Fuel Valve Switch 29

Fuel Volume Indicator.... 31

G

Ground System.... 56

Ground Terminal.... 32

H

Handling Gasoline 20

High Altitude Jets 69

Hot Exhaust Caution 26

Hot Exhaust Systems 18

How To Obtain Warranty

Service 95-96

|

Ignition Key Switch 30

Indicator Light 30

Introduction 7

L

Lift Mount

Operation 57

Loose Parts.... 35

Lubricants.... 87

M

Maintenance 61

Fuel Line 70

Periodic Maintenance Chart..... 65

Safety 63

Maintenance Log.... 103

Modifications 19

N

Noise 22

Normal Spark Plug.... 73

0

Oil 87

Oil Change.... 68

Oil Level Inspection.... 67

Oil Recommendation.... 66

Operation Rules 21

Operator Safety...... 11

P

Periodic Maintenance.... 64

Pre-Operation Inspection 44

Problems Affecting Emissions ..... 59

R

Recommended Fuel...... 42

Refueling 45

Replacement Parts 60

S

Safety 11

Electrical 15

Operating Without Instruction .... 12

Precautions.... 64

Safety Labels

General Warning 25

Safety Labels and Locations ..... 24

Safety Symbols......8

Signal Words......8

Source of Emissions 59

Spark Arrester 74

Spark Plug

Replacement 73

Spark Plug Inspection.... 72

Specifications 85

Starter Recoil Grip 31

Starting the Engine 47

Electric.... 47

Recoil 48

Stopping the Engine.... 48

Storage

Drain Fuel 79

Removal.... 82

Stabilize Fuel.... 79

Storage Precautions.... 82

Storage Preparation.... 78

System Requirements

Standby Power 56

T

Tool Kit.... 62

Trademarks.... 2

Transporting 83

Troubleshooting

Engine Backfires 90

Engine Lacks Power 90

Engine Loses Power 92

Engine Misfires 91

Engine Pings or Knocks 90

Engine Runs Irregularly 91

Engine Stalls 91

Engine Stops.... 92

Engine Turns Over But Will Not

Start.... 89

Engine Will Not Turn Over ..... 89

Lean Fuel 91

No Power at AC Receptacles .... 92

No Power at DC Receptacles .... 92

Rich Fuel 91

U

U.S. and California Clean Air

Acts 59

Unboxing 35

V

Vehicle Identification Numbers .....9

W

Warning Symbols 8

Warranty

Fluids.... 95

Limitations 94

Limited Warranty 93

Lubricants.... 95

Registration.... 93

Remedies 94

Wet Fouled Plug.... 73

Wheel Locks.... 46

AVERTISSEMENT

Technical line drawing of a portable electric vehicle chassis with visible wheels, motors, and control panel (no text or symbols)

Blue circular icon with a white silhouette of a person reading a book (no text or symbols)

CONSOMMATION D'ALCOOL, DE MÉDICAMENTS OU DE DROGUES

AVERTISSEMENT

Technical illustration of a wheeled cart with visible wheels and a yellow belt, labeled with number 1 (no text or symbols on the diagram itself)

ATTENTION

Illustration of a yellow industrial vehicle chassis with wheels and motors (no text or symbols)

AVIS

MANUTENTION DE L'ESSENCE

AVERTISSEMENT

Technical diagram of a vehicle chassis with numbered components for identification

Black silhouette of a flame with flame-like edges (no text or symbols)

Abstract black-and-white graphic of a stylized human figure with dotted pattern and a central circular element (no text or symbols)

Silhouette of a hand reaching toward a textured surface with wavy lines (no text or symbols)

CARACTÉRISTIQUES ET COMMANDES APERÇU

Technical diagram of a lawn mower with numbered parts for identification

CARACTÉRISTIQUES ET COMMANDES

Labeled diagram of a device rear panel with numbered components and electrical connectors

Diagram showing a green curved arrow pointing to a yellow circular component with a handle, surrounded by circular elements (no text or symbols)

Diagram showing a yellow circular component with a green curved arrow indicating rotation or direction, surrounded by circular elements (no text or symbols)

Close-up of a computer mouse with a yellow circular button labeled '1' and a bird icon, no readable text or symbols beyond the button.

TÉMOIN LUMINEUX

Close-up of a yellow spherical object with threaded end and labeled point '1' (no text or symbols on the object itself)

IMPORTANT

Technical line drawing of a tractor's front wheel and side panel (no text or symbols)

Illustration of a yellow plastic component with a magnified inset showing its tip (no text or symbols)

POIGNÉE DE DÉMARREUR

AVIS

Diagram of a vehicle's front view and side view showing a yellow plastic component with a magnified inset (no text or symbols)

Close-up of a mechanical component with a highlighted green component and an inset showing a yellow threaded component (no text or symbols visible)

Diagram showing two labeled components (1 and 2) with green arrows pointing to a mechanical or electronic component, possibly indicating directional movement or assembly.

DISJONCTEURS DE 120 V

Diagram of a computer control panel with labeled buttons and ports, showing numbered labels 1 to 4.

Illustration of two yellow electrical connectors mounted on a wall with mounting holes and screws (no text or symbols)

PRISE À VERROUILLAGE PAR ROTATION DE 120 V C.A./240 V C.A.

Illustration of a yellow circular object with a ring above it, mounted on a white shelf (no text or symbols)

P5500I P6500I
TENSION	INTENSITÉ DE COURANT	TENSION	INTENSITÉ DE COURANT
120 V 46 A 120 V 54 A
240 V 23 A 240 V 27 A

PRISE C.C.

3D-rendered white geometric shape with two vertical cutouts, no text or symbols present

ASSEMBLAGE

IMPORTANCE D'UN ASSEMBLAGE ADÉQUAT

AVERTISSEMENT

Illustration showing five types of medical or laboratory items: rolled documents, blood vessels, blood cells, and earthen tube samples with numbered labels.

Technical diagram showing various dental tools and components with numbered labels

AUTRES ÉLÉMENTS COMPRIS

Technical diagram of a vehicle's suspension system with numbered components for identification

RECHANGE

No DE RÉF.	DESCRIPTION	QUANTITÉ
1	Essieu 2
2	Entretoise 4
3	Roue 4
4	Rondelle 4
5	Circlip 4

ASSEMBLAGE

3D diagram showing a yellow pipe with a purple downward arrow and a green circular component, labeled with number 5 (no text or symbols on the diagram itself)

MÉCANISMES DE VERROUILLAGE DE ROUE

Technical line drawing of a vehicle chassis with wheels and internal components (no text or symbols)

RECHANGE

3D illustration of a yellow mechanical clamp device with attached metal bracket and two hanging weights, no text or symbols present

COUPLE

Technical diagram of a yellow mechanical component with numbered parts labeled 9, 10, and 11.

RECHANGE

Illustration of a red spray can pouring liquid into a vehicle chassis with visible wheels and hoses (no text or symbols)

Line drawing of a lawn mower with labeled parts (no text or symbols on the diagram itself)

INSPECTION PRÉALABLE

AVERTISSEMENT

Hand-drawn diagram showing a mechanical device with a green arrow indicating rotational motion, labeled with number 1.

Diagram showing two steps of a yellow mechanical component with labeled parts, including a pin and base.

① ARRÊT
② MARCHE

LANCEUR À RAPPEL

Illustration of a yellow mechanical component with a numbered label (1) and no visible text or symbols

TENGLISH LEVEL ATHROOM TEST RESET RESET TEST TEST FOLLOW DIRECTIONS SAVEZ INSTRUCTION TENGLISH LEVEL ATHROOM TEST RESET RESET TEST FOLLOW DIRECTIONS SAVEZ INSTRUCTION 1

Simple 3D-rendered white object with two vertical slots inside a rounded rectangle (no text or symbols)

Illustration of a yellow screw component with a magnified inset showing its tip (no text or symbols present)

EXIGENCES RELATIVES AU SYSTÈME

Line drawing of a portable electric vehicle with a crane hook attached (no text or symbols)

ATTENTION

Labeled photo of six different types of electrical connectors or tools, numbered 1 to 6.

Technical diagram of a mechanical assembly with a yellow circular component and numbered label (1), no readable text or symbols present.

Diagram of a yellow plastic component mounted on a vehicle wheel, with no visible text or symbols

IMPORTANT

Technical line drawing of a mechanical assembly with pipes and components (no text or symbols)

REPLACEMENT D'UNE BOUGIE

IMPORTANT

3D rendering of a cylindrical mechanical component with a mesh grille and labeled part (1), no text or symbols present.

Technical line drawing of a tractor's wheel and chassis (no text or symbols)

BATTERIE

! AVERTISSEMENT

Technical illustration of a vehicle chassis with wheels and a yellow battery block (no text or symbols)

INSTALLATION DE LA BATTERIE

Simple line drawing of a yellow capsule on a circular plate with a numbered label (1), no text or symbols present.

STABILISATION DU CARBURANT

AVERTISSEMENT

Technical line drawing of a vehicle chassis frame with a highlighted yellow component (no text or symbols)

ROBINET DE CARBURANT

Mechanical assembly diagram showing a yellow valve mounted on a shaft with a green downward arrow indicating a component (no text or symbols present)

CARBURATEUR

Technical illustration of a mechanical assembly with a blue component and pipe (no text or symbols)

BRUMISATION DU MOTEUR

Technical diagram of a mechanical assembly with pipes and a hand operating a valve (no text or symbols)

Technical diagram showing three labeled components: a cylindrical component, a cross-sectional view, and a separate circular component with internal features.

SPÉCIFICATIONS

P5500/P6500

AUCUNE ALIMENTATION AU NIVEAU DES PRISES C.A.

GARANTIE ET EXCLUSIONS

LIMITATIONS DE GARANTIE ET RECOURS