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Polaris Sportsman S User's Manual

1. 52 Premium 4 Synthetic Lubricant 78 PYT Drying 35666 30s a he so eae 105 PVT System 104 105 R Radiator Coolant Level 89 Rear Gearcase Oil 600 700 87 Reat Sprig ni e aene r thoes 114 Rider Information Center 46 49 S Safe Riding Gear 10 SAFETY y ice ninan hae Bon 6 35 Safety Decals and Locations 6 9 Safety Training 11 Setting the Parking Brake 40 Side Panel Removal 93 136 S SIMSHUIN Goce 516s wrereyenlorgacier se sienas 61 Spark Arrestor 0 103 Spark Plug Replacement 101 spark Plugs ss coos eerste is e 101 SPECIFICATIONS 122 129 Starting a Cold Engine 53 Starting a Warm Engine 54 Starting the Engine 53 54 Steering Assembly 92 ST TA LE aiaa tyr vcn s n nce ts 110 113 Storage Tips 111 113 T TABLE OF CONTENTS 5 TaChOmeters isro riag tan Cona ENA 47 Taillight Brakelight Lamp Replacement 100 Throttle Cable Freeplay 116 Throttle Lever 0 0000 37 TIES paps g52e eeds ceases as eas 3 94 Toe Alignment 92 Transmission Oil 400 500 83 Transmission Oil 600 700 85 Transporting the ATV 113 Traveling Downhill 62 Traveling Uphill 0 60 Trip Meters enean a gabari apes 47 TROUBLESHOOTIN
2. Front Wheel Hub Tightening Front wheel bearing tightness and spindle nut retention are critical component operations All service must be performed by your authorized Polaris dealer 95 MAINTENANCE AND LUBRICATION Filter Systems Air Filter Service 1 5 6 Remove the seat release the 1 air box cover clips and 2 remove the air box cover Loosen the clamp and remove the filter Remove the fabric type pre filter 1 from the main filter 2 Wash the pre filter in soapy water then rinse and let dry Reinstall the pre filter over the main filter Replace the main filter if needed Reinstall the filter into the air box and tighten the clamp Do not over tighten the clamp as filter damage could occur Reinstall the air box cover and the seat Breather Filter Hose 1 96 To access the breather filter 3 remove the left side panel as outlined on page 93 The breather filter is on the hose that runs between the engine and air box Remove the clamps and pull the filter out of the hoses NOTE It s not necessary to remove the lower hose from the engine Inspect the filter for debris Blow gently through the filter in the direction of the arrow to check for clogging Replace if needed Check the hoses for cracks deterioration abrasion or leaks Replace as needed Reinstall the filter and secure the clamps NOTE The filter is effective with the arrow pointing in either direction CAUTI
3. By switching to low range while operating at low ground speeds the air temperature in the clutch cover is reduced by almost 160 degrees Reducing the temperature inside the clutch cover extends the life of the PVT components belt cover etc When To Use Low Range vs High Range Following is a guideline for when to use low range and high range Low Range e When basic operation is at speeds less than 7 MPH 11 KPH For heavy pulling e When operating in rough terrain swamps mountains etc at low ground speeds High Range e When basic operation is at speeds greater than 7 MPH 11 KPH e When operating at high ground speeds 104 MAINTENANCE AND LUBRICATION PVT System AWARNING Failure to comply with the instructions in this warning can result in severe injury or death Do not modify any component of the PVT system Doing so may reduce its strength so that a failure may occur at a high speed The PVT system has been precision balanced Any modification will cause the system to be out of balance creating vibration and additional loads on components The PVT system rotates at high speeds creating large amounts of force on clutch components Extensive engineering and testing has been conducted to ensure the safety of this product However as the owner you have the following responsibilities to make sure this system remains safe Always follow all recommended maintenance procedures See your dealer as outlined in the
4. Driving Safely Driving Over Obstacles Be alert Look ahead and learn to read the terrain you re traveling on Be constantly alert for hazards such as logs rocks and low hanging branches AWARNING Severe injury or death can result if your vehicle comes in contact with a hidden obstacle Not all obstacles are immediately visible Travel with caution in unfamiliar terrain 65 OPERATION Driving Safely Driving in Reverse Follow these precautions when operating in reverse 1 2 3 Always avoid backing downhill Back slowly When in reverse apply the brakes lightly for stopping o on Avoid turning at ae sharp angles in reverse Never open the throttle suddenly while backing AWARNING Failure to use caution when operating in reverse can result in serious injury or death Before shifting into reverse always check for obstacles or people behind the vehicle When it s safe to proceed back slowly Do not use the override switch unless additional power is required for vehicle movement Use with caution Avoid backing on inclines and avoid turning at sharp angles NOTE Your Polaris ATV is equipped with a reverse speed limiter The override button should be used with caution as rearward vehicle speed is greatly increased Do not operate at wide open throttle Open the throttle just enough to maintain a desired speed CAUTION Excessive throttle operation while in the speed limit mode may
5. Polaris 4 wheel drive ATVs are equipped with a unique Polaris exclusive AWD system which is activated by a switch 1 on the right handlebar When the switch is off the ATV is in 2 wheel drive at all times When the switch is on the ATV is in AWD and the AWD indicator light in the instrument cluster will be on When in AWD the front gearcase will automatically engage any time the rear wheels lose traction When the rear wheels regain traction the front gearcase will automatically disengage NOTE The override switch allows activation of AWD in reverse if the AWD switch is on See page 36 There is no limit to the length of time the vehicle may remain in AWD Engaging Front Gearcase The AWD switch may be turned on or off while the vehicle is moving Initially the vehicle s electronic system will not enable the AWD until the engine RPM is below 3100 Once enabled the AWD remains enabled until the AWD switch is turned off If the switch is turned off while the front gearcase is moving it will not disengage until the rear wheels regain traction Engage the AWD switch before getting into conditions where front wheel drive may be needed If the rear wheels are spinning release the throttle before switching to AWD CAUTION Switching to AWD while the rear wheels are spinning may cause severe drive shaft and gearcase damage Always switch to AWD while the rear wheels have traction or are at rest 44 FEATURES Inst
6. ZAWARNING The engine exhaust from this product contains chemicals known to cause cancer birth defects or other reproductive harm A card containing important ATV safety information should be attached to the owner s manual on the next page If you cannot locate this card or if it has been removed please call 1 800 342 3764 for assistance We ve created a web site just for YOU Technical tips New product introductions Event schedules Parts and Service Manual information Exciting details about The Way Out Check it out www polarisindustries com owner PELARIS The Way Out All information in this manual is based on the latest product data and specifications available at the time of printing Polaris Industries Inc reserves the right to make product changes and improvements that may affect illustrations or explanations No part of this manual shall be reproduced or used without the written permission of Polaris Industries Inc Copyright 2002 Polaris Industries Inc All Rights Reserved Printed in the U S A WELCOME Thank you for purchasing a Polaris vehicle and welcome to our world wide family of Polaris owners We proudly produce an exciting line of utility and recreational products Polaris Recreational Vehicles e Snowmobiles e All terrain vehicles ATVs e Watercraft e RANGER utility vehicles e Victory motorcycles Polaris Professional Series Workmobiles e Utility Task Vehicles UTV
7. exclusive option repair or replacement of any defective materials or 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 Some states do not permit the exclusion or limitation of incidental or consequential damages or implied warranties so the above limitations or exclusions may not apply to you if inconsistent with controlling state law 131 WARRANTY ALL IMPLIED WARRANTIES INCLUDING BUT NOT LIMITED TO THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE ARE LIMITED IN DURATION TO THE ABOVE SIX MONTH WARRANTY PERIOD POLARIS FURTHER 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 to you if inconsistent with controlling state law HOW TO OBTAIN WARRANTY SERVICE If your ATV requires warranty service you must take it to a Polaris dealer authorized to repair Polaris ATVs When requesting warranty service you must present your copy of the Warranty Registration form to the dealer THE COST OF TRANSPORTATION TO AND FROM THE DEALER IS YOUR RESPONSIBILITY Polaris suggests tha
8. Never operate at excessive speeds Travel at speeds appropriate for the terrain visibility and operating conditions and your experience Never attempt wheelies jumps or other stunts Always inspect your ATV before each use to make sure it s in safe operating condition Always follow the inspection and maintenance procedures and schedules outlined in your owner s manual Always keep both hands on the handlebars and both feet on the foot rests of the ATV during operation Always travel slowly and use extra caution when operating on unfa miliar terrain Be alert to changing terrain conditions Never operate on excessively rough slippery or loose terrain Always follow proper turning procedures as described in this manu al Practice turning at low speeds before attempting to turn at faster speeds Do not turn at excessive speeds 13 SAFETY Operator Safety Always have the ATV inspected by an authorized Polaris dealer if it s been involved in an accident Never operate on hills too steep for the ATV or for your abilities Practice on smaller hills before attempting larger hills Always follow proper procedures for climbing hills Check the ter rain carefully before ascending a hill Never climb hills with exces sively slippery or loose surfaces Shift your weight forward Never open the throttle suddenly or make sudden gear changes Never go over the top of a hill at high speed Always follow proper procedures for goin
9. Release the parking brake 5 Slowly depress the throttle with your right thumb and begin driving Vehicle speed is controlled by the amount of throttle opening 6 Drive slowly Practice maneuvering and using the throttle and brakes on level surfaces 57 OPERATION Driving Safely Making Turns Your ATV is equipped with a solid rear axle which drives both rear wheels equally at all times This means that the wheel on the outside of the turn must travel a greater distance than the inside wheel when turning and the inside tire must slip traction slightly To turn steer in the direction of the turn leaning your upper body to the inside of the turn while supporting your weight on the outer footrest This technique alters the balance of traction between the rear wheels allowing the turn to be made smoothly The same leaning technique should be used for turning in reverse NOTE Practice making turns at slow speeds before attempting to turn at faster speeds AWARNING Turning at sharp angles or at excessive speeds can result in vehicle overturn and lead to serious injury Avoid turning at sharp angles Never turn at high speeds 58 OPERATION Driving Safely Driving on Slippery Surfaces Whenever riding on slippery surfaces such as wet trails or loose gravel or during freezing weather follow these precautions 1 2 3 Slow down when entering slippery areas Maintain a high level of alertnes
10. Spring Meters 0 1800 10 MH Blue Green White Yellow EBS Feet 0 6000 PN 5630513 PN 7041157 PN 7041635 PN 5132751 1800 3700 10 WH Blue Green White Yellow EBS 6000 12000 PN 5630710 PN 7041157 PN 7041635 PN 5132751 EBS models require no helix spring adjustment 127 SPECIFICATIONS SPORTSMAN 700 1240 Tbs 503 ke Fuel Capacity 4 75 gal 18 1 Towing Rating 1500 Ibs 681 kg Unbraked Trailer Towing Capacity 1914 Ibs 868 kg Front Rack Capacity 100 Ibs 45 4 kg Rear Rack Capacity 200 Ibs 90 7 kg 200 lbs 907 k8 e O tongue weight not to exceed 200 lbs 90 8 kg Tin 279 em 740 Tbs 336 ke EOSALOETI 135 es Based on EU Directive 76 432 EC 128 SPECIFICATIONS SPORTSMAN 700 Shift Type Side Lever High Low Neutral Reverse Park Gear Reduction Low 7 5 1 Gear Reduction Reverse 5 11 1 Gear Reduction High 2 89 1 Drive Ratio Front 3 82 1 Drive Ratio Final 3 10 1 Tire Size Front 25x8 12 Tire Size Rear 25x 11 12 Front Brake Hydraulic Disc Rear Brake Hydraulic Parking Brake Hydraulic lock all wheel Headlight watts 1 Single Beam on Handlebar 50 2 Single Beam on Grill 27 Taillights watts 8 26 Brake Light watts 26 9 Instrument Cluster LCD Jetting and Clutching Charts Sportsman 700 Altitude AMBIENT Below 40 F 40 F and above TEMPERATURE Below 5 C 5 C and above Meters 0 1800 Feet 0 6000 1800 3700 6000 12000 Altitud
11. fasteners p gt Air filter Pre Ride Pre Ride Inspect clean Pre cleaner Coolant level Pre Ride Pre Ride Replace coolant every two years Fuel tank and Pre Ride Pre Ride Fill to proper levels engine oil Engine stop switch Check operation gt More often under severe use such as dirty or wet conditions Emission Control System Service California m Dealer service item 70 MAINTENANCE AND LUBRICATION Periodic Maintenance Schedule Hours Frequency Miles Air box sediment Pre Ride Pre Ride Drain deposits whenever tube visible Headlamp Pre Ride Pre Ride Check operation daily ap ply Polaris dielectric grease to connector when replaced Tail lamp brake Pre Ride Pre Ride Check operation daily ap lamp ply Polaris dielectric grease to socket when replaced Air filter Weekly Weekly Inspect replace as needed main element Transmission oil 20 hrs Monthly Inspect monthly change level annually Battery 20 hrs Monthly Check terminals clean check fluid level if applica ble p gt Engine breather 20 hrs Monthly Inspect replace annually filter and as needed Brake pad wear Monthly Inspect periodically Front and rear 100 hrs Monthly Check monthly change gearcase oil annually General lubrication 50 hrs 3 months Lubricate all fittings pivots cables etc gt Engine oil level oil 100 hrs 6 months Check level daily break in change 1000 service at one month miles cha
12. override button until the total changes to 0 NOTE In the Rider Information Center the trip meter display contains a decimal point but the odometer displays without a decimal point Mode 3 Hour Meter This mode logs the total hours the engine has been in operation Mode 4 Tachometer The engine RPM is displayed digitally NOTE Small fluctuations in the RPM from day to day may be normal because of changes in humidity temperature and elevation 47 FEATURES Instrument Cluster Rider Information Center Diagnostic Mode The diagnostic mode is for informational purposes only Please return your ATV to your dealer for all major repairs As long as the gauge is in the diagnostic mode the wrench icon will remain lit To leave the diagnostic mode either shift the machine out of neutral or turn the key switch off and on NOTE Any movement of the tires will also take the machine out of the diagnostic mode To enter the diagnostics mode 1 Turn the key switch off and wait 10 seconds 2 Set the park brake and shift the transmission to neutral 3 Hold the mode reverse override button and turn the key switch on 4 Release the switch as soon as the display is activated The initial screen display refers to the software version installed in your ATV This information is displayed briefly Use the mode reverse override button to toggle through the diagnostic screens Screen 1 Battery voltage Screen 2 Tachometer Sc
13. system is enabled g Tach Trip Odo Engine Hour Display Indicator 1 Service Interval Diagnostic Mode Indicator Low Battery and Over Voltage This warning usually indicates that the ATV is being operated at an RPM too low to keep the battery charged A low battery warning may also occur under normal operation if the machine is at idle and high electrical load lights cooling fan accessories is applied Driving at a higher RPM or connecting a battery charger will usually clear the warning Odometer Tachometer Tripmeter Hour Meter Check Engine Warning Indicator The word HOT will display alphanumerically when the engine is overheating Do not continue to operate the ATV if this warning appears or serious engine damage could result Mode Indicator FEATURES Instrument Cluster Rider Information Center The rider information center has 4 standard modes Mode 1 Odometer Mode 2 Tripmeter Mode 3 Total Service Hours Mode 4 Tachometer The reverse override button on the left handlebar is also the mode button NOTE If using the mode button to program the rider information center or to toggle through the options the machine cannot be in reverse Mode 1 Odometer The odometer records the miles traveled by the ATV Mode 2 Trip Meter The trip meter records the miles traveled by the ATV on each trip if it s reset before each trip To reset the trip meter select the trip meter mode Press and hold the mode button
14. AWARNING Battery electrolyte is poisonous It contains sulfuric acid Serious burns can result from contact with skin eyes or clothing Antidote External Flush with water Internal Drink large quantities of water or milk Follow with milk of magnesia beaten egg or vegetable oil Call physician immediately Eyes Flush with water for 15 minutes and get prompt medical attention Batteries produce explosive gases Keep sparks flame cigarettes etc away Ventilate when charging or using in an enclosed space Always shield eyes when working near batteries KEEP OUT OF REACH OF CHILDREN 106 MAINTENANCE AND LUBRICATION Battery Battery Removal 1 Disconnect the hold down strap holding the battery in position and remove battery cover On conventional batteries remove the battery vent tube Disconnect the black negative battery cable first Disconnect the red positive battery cable next ce ai O Lift the battery out of the ATV Be careful not to tip a conventional battery sideways which could spill electrolyte 4 CAUTION If electrolyte spills immediately wash it off with a solution of one tablespoon baking soda and one cup water to prevent damage to the vehicle Battery Installation 1 Set the battery in the battery holder 2 With conventional batteries install the battery vent tube sealed batteries do not have a vent tube NOTE The vent tube must be free of obstructions and securely installed If n
15. Always maintain proper tire pressure as described in the owner s manual and on safety decals 4 WARNING POTENTIAL HAZARD Operating the ATV with improper modifications WHAT CAN HAPPEN Improper installation of accessories or modification of the ATV may cause changes in handling which could lead to an accident HOW TO AVOID THE HAZARD Never modify the ATV through improper installation or use of accessories All parts and accessories added to the vehicle must be genuine Polaris Industries Inc or equivalent components designed for use on this ATV and should be installed and used according to approved instructions See your authorized Polaris ATV dealer for more information 33 SAFETY Operator Safety 34 4 WARNING POTENTIAL HAZARD Overloading the ATV or carrying towing cargo improperly WHAT CAN HAPPEN Overloading and towing can cause changes in vehicle handling which could lead to loss of control or an accident HOW TO AVOID THE HAZARD Never exceed the stated load capacity for this ATV Cargo should be properly distributed and securely attached Reduce speed when carrying cargo or pulling a trailer Allow a greater distance for braking Always follow the instructions in the owner s manual for carrying cargo or pulling a trailer 4 WARNING POTENTIAL HAZARD Operating on frozen bodies of water WHAT CAN HAPPEN Severe injury or death can result if the ATV and or the operator fall through the ice
16. Around on a Hill AWARNING Improper hill climbing procedures could cause loss of control or overturn and result in serious injury or death Avoid climbing steep hills 25 maximum Use extreme caution when operating on hills and follow proper operating procedures outlined in the owner s manual If the vehicle stalls while climbing a hill never back it down the hill One maneuver that can be used when you must turn around while climbing a hill is the K turn 1 Stop and lock the parking brake while keeping body weight uphill 2 Leave the transmission in forward and shut off the engine 3 Dismount on the uphill side of the vehicle or on the left if the vehicle is pointing straight uphill 4 Staying uphill of the vehicle turn the handlebars full left 5 While holding the service brake release the parking brake lock and slowly allow the vehicle to roll around to your right until it s pointing across the hill or slightly downward 6 Lock the parking brake and remount the vehicle from the uphill side keeping body weight uphill 7 Restart the engine with the transmission still in forward 8 Release the parking brake and proceed slowly controlling speed with the service brake until the vehicle is on more level ground t Uphill 63 OPERATION Driving Safely Driving Through Water Your ATV can operate through water with a maximum recommended depth equal to the bottom of the footrests 1 Follow these proce
17. POTENTIAL HAZARD Operating the ATV through deep or fast flowing water WHAT CAN HAPPEN Tires may float causing loss of traction and loss of control which could lead to an accident or overturn HOW TO AVOID THE HAZARD Avoid operating the ATV through deep or fast flowing water If it s unavoidable to enter water that exceeds the recommended maximum depth see page 64 travel slowly balance your weight carefully avoid sudden movements and maintain a slow and steady forward motion Do not make sudden turns or stops and do not make sudden throttle changes Wet brakes may have reduced stopping ability Always test the brakes after leaving water If necessary apply them several times to let friction dry out the pads 4 WARNING POTENTIAL HAZARD Improperly operating in reverse WHAT CAN HAPPEN The ATV could collide with an obstacle or person resulting in severe injury HOW TO AVOID THE HAZARD Before shifting into reverse gear always check for obstacles or people behind the ATV When it s safe to proceed back slowly 32 SAFETY Operator Safety A WARNING POTENTIAL HAZARD Operating this ATV with improper tires or with improper or uneven tire pressure WHAT CAN HAPPEN Use of improper tires or operation of the ATV with improper or uneven tire pressure could cause loss of control or accident HOW TO AVOID THE HAZARD Always use the size and type of tires specified for the ATV in the owner s manual
18. and cause serious injury or death When removing the battery always disconnect the negative black cable first When reinstalling the battery always connect the negative black cable last Battery Charging Sealed Battery The following battery charging instructions apply only to the installation of a YUASA activated sealed battery Read all instructions before proceeding with the installation of this battery The YUASA activated sealed battery is already filled with electrolyte and has been sealed and fully charged at the factory Do not ever pry the sealing strip off or add any other fluid to this battery The single most important thing to maintaining a sealed battery is to keep it fully charged Since the battery is sealed and the sealing strip cannot be removed you must use a voltmeter or multimeter to measure DC voltage 108 MAINTENANCE AND LUBRICATION Battery Battery Charging Sealed Battery For a refresh charge follow all instructions carefully 1 Check the battery voltage with a voltmeter or multimeter A fully charged battery will register 12 8 V or higher 2 Ifthe voltage is less than 12 8 volts recharge the battery NOTE When using an automatic charger refer to the charger manufacturer s instructions for recharging When using a constant current charger use the following guidelines for recharging AWARNING An overheated battery could explode causing severe injury or death Always watch charging
19. and free of burrs nicks or scratches 5 Reinstall the drain plug and torque to 14 17 ft Ibs 19 23 Nm 6 Disconnect the lower oil delivery hose and remove the screen fitting 3 from the oil tank Clean and reinstall the fitting torquing to 25 ft lbs Reattach the oil line NOTE The fitting threads must be sealed with Loctite PST 505 or PTFE seal tape The fitting must also line up with the mark 4 on the rear side of the oil tank 80 MAINTENANCE AND LUBRICATION Oil Change 400 500 7 8 10 11 12 13 14 15 16 Place shop towels beneath the oil filter Using an oil filter wrench turn the filter 1 counterclockwise and remove Lubricate the gasket on the new filter with a film of new engine oil Check to make sure the gasket is in good condition Also make sure the gasket from the old filter is not still on the engine Install the new filter and tighten by hand 1 2 to 3 4 turn after gasket contacts the engine Approximately one cup of engine oil will remain in the crankcase To drain remove the drain plug on the lower right side of the crankcase NOTE The sealing surfaces on the drain plug and crankcase should be clean and free of burrs nicks or scratches After draining reinstall the drain plug 4 CAUTION Loss of oil pump prime could result in engine damage It s extremely important to drain refill and start the engine in an expedient manner Do not al
20. in reverse if the AWD switch is on This switch is also used to toggle through the different modes of the rider information center See page 45 Engine Stop Switch 2 The engine will not start or run when the switch is in the OFF RUN OFF OFF position Its purpose is to provide the operator with a quick means of engine ha shutdown in case of an emergency Main Switch 3 To start the engine slide the stop switch to the center RUN position and turn the main key switch clockwise past the ON position Release the key when the engine starts NOTE Both the main switch and the emergency engine stop switch will shut off all electrical power to the vehicle including lights To stop the engine slide the stop switch either right or left to the OFF position 36 CONTROLS AWARNING Operating an ATV with sticking or improperly operating throttle controls could cause an accident and lead to severe injury or death Never start or operate an ATV with a sticking or improperly operating throttle Always contact your dealer for service if throttle problems arise Failure to check or maintain proper operation of the throttle system can result in an accident if the throttle lever sticks during operation Always check the lever for free movement and return before starting the engine Also check occasionally during operation Throttle Lever Engine speed and vehicle movement are controlled by pressing the throttle le
21. in starting it or not NOTE If water has been ingested into the PVT follow the procedure on page 105 for drying out the PVT 102 MAINTENANCE AND LUBRICATION Spark Arrestor AWARNING Failure to heed the following warnings while servicing the spark arrestor could result in serious injury or death Do not perform service on the spark arrestor while the system is hot Exhaust system temperatures can reach 1000 F Allow components to cool sufficiently before proceeding Remove any combustible materials from the area Wear eye protection Do not stand behind or in front of the vehicle while purging Never run the engine in an enclosed area Exhaust contains poisonous carbon monoxide gas Never go under the vehicle while it s inclined Use the following procedure to periodically purge accumulated carbon from the exhaust pipe muffler 1 Remove the arrestor clean out plug 1 from the bottom of the muffler Place the transmission in neutral or PARK if equipped and start the engine Purge carbon from the system by ae A momentarily revving the engine several times If carbon is expelled cover or plug the exhaust outlet 2 and rap on the pipe around the cleanout plug while revving the engine several more times If particles are still suspected to be in the muffler elevate the rear of the vehicle one foot higher than the front Set the parking brake and block the wheels Make sure the vehicle is in neu
22. inside of the right footrest The hydraulic auxiliary brake system will not require adjustment NOTE Since this is a rear brake only it will not be as effective as the all wheel system 91 MAINTENANCE AND LUBRICATION Toe Alignment AWARNING Severe injury or death can result from improper toe alignment and adjustment Do not attempt to adjust tie rod alignment All tie rod adjustments should be performed by an authorized Polaris dealer Use the following procedure to check the toe alignment of the vehicle The recommended toe alignment is 1 8 to 1 4 toe out 1 Set the handlebars in a za rie straight ahead position ee N NOTE The steering frog Swe koe N ee can be used as an indicator wee Sata of whether the handlebars are RS straight The frog should Ne always point straight back from the steering post 2 Place stands 1 in front of the vehicle perpendicular to the rear tires See illustration 3 Tie an elastic string around the stands making sure the string just touches the side surface of the rear tires on each side of the vehicle and goes around the stands in front of the vehicle 2 4 Measure the distance from the string to the rim at the 1 front and rear of the front rim 3 Rear measurement should be 1 16 1 8 2 to 3 cm more than the front measurement NOTE If you discover improper alignment see your Polaris dealer for service Steering Assembly The stee
23. lead to a collision or overturn HOW TO AVOID THE HAZARD Always follow proper procedures for turning as described in the owner s manual Practice turning at slow speeds before attempting to turn at faster speeds Never turn at excessive speed 4 WARNING POTENTIAL HAZARD Operating on excessively steep hills WHAT CAN HAPPEN The vehicle may overturn HOW TO AVOID THE HAZARD Never operate on hills too steep for the ATV or for your abilities Never operate the ATV on hills steeper than 25 Practice on smaller hills before attempting large hills 26 SAFETY Operator Safety 4 WARNING POTENTIAL HAZARD Climbing hills improperly WHAT CAN HAPPEN Improper hill climbing could cause loss of control or overturn HOW TO AVOID THE HAZARD Always follow proper procedures for climbing hills as described in the owner s manual Always check the terrain carefully before ascending any hill Never operate the ATV on hills steeper than 25 Never climb hills with excessively slippery or loose surfaces Shift your weight forward Never open the throttle suddenly while traveling uphill The ATV could flip over backwards Never go over the top of any hill at high speed An obstacle a sharp drop or another vehicle or person could be on the other side of the hill 27 SAFETY Operator Safety 4 WARNING POTENTIAL HAZARD Traveling downhill improperly WHAT CAN HAPPEN Improperly descending a hill could c
24. of the vehicle and creates a less stable operating condition e SECURE ALL LOADS BEFORE OPERATING Unsecured loads can create unstable operating conditions which could result in loss of control of the vehicle e OPERATE ONLY WITH STABLE AND SAFELY ARRANGED LOADS When handling off centered loads that cannot be centered securely fasten the load and operate with extra caution Always attach the tow load to the hitch point designated for your vehicle e HEAVY LOADS CAN CAUSE BRAKING AND CONTROL PROBLEMS Use extreme caution when applying brakes with a loaded vehicle Avoid terrain or situations that may require backing downhill e USE EXTREME CAUTION when operating with loads that extend over the rack sides Stability and maneuverability may be adversely affected causing the vehicle to overturn e DO NOT BLOCK THE FRONT HEADLIGHT BEAM when carrying loads on the front rack e DO NOT TRAVEL FASTER THAN THE RECOMMENDED SPEEDS Vehicle should never exceed 10 mph 16 kph while towing a load on a level grass surface Vehicle speed should never exceed 5 mph 8 kph when towing loads in rough terrain while cornering or while ascending or descending a hill 56 OPERATION Driving Safely Driving Procedures 1 Sit upright with both feet on the footrests and both hands on the handlebars 2 Start the engine and allow it to warm up then shift the transmission into gear 3 Check your surroundings and determine your path of travel 4
25. of the vehicle or make any other modifications to the vehicle for these purposes Any modifications to the original equipment of the vehicle create a substantial safety hazard and increase the risk of bodily injury The warranty on your Polaris ATV is terminated if any equipment has been added to the vehicle or if any modifications have been made to the vehicle that increase its speed or power NOTE The addition of certain accessories including but not limited to mowers blades tires sprayers or large racks may change the handling characteristics of the vehicle Use only Polaris approved accessories and familiarize yourself with their function and effect on the vehicle 15 SAFETY Operator Safety 16 A WARNING POTENTIAL HAZARD Operating this ATV without proper instruction WHAT CAN HAPPEN The risk of an accident is greatly increased if the operator does not know how to operate the ATV properly in different situations and on different types of terrain HOW TO AVOID THE HAZARD Beginning and inexperienced operators should complete the certified training course offered by Polaris Operators should regularly practice the skills learned in the course and the operating techniques described in the owner s manual For more information about the training course contact an authorized ATV dealer or call Polaris at 1 800 342 3764 4 WARNING POTENTIAL HAZARD Failure to follow the age recommendations for this ATV WHAT
26. overheating or engine damage See your Polaris dealer for more information about jetting the ATV for conditions in your area 115 ADJUSTMENTS Throttle Cable Freeplay Throttle cable freeplay is adjusted at the handlebar 1 Slide the boots 1 off the inline cable adjuster sleeve 2 Loosen the adjuster locknut 3 2 Turn the adjuster until 1 16 to 1 8 freeplay is achieved at the thumb lever NOTE While adjusting freeplay be sure to flip the throttle lever back and forth 3 Tighten the locknut and slide the boots over the cable adjuster until they touch at the midpoint of the adjuster 1 2 1 116 TROUBLESHOOTING Drive Belt and Cover Problems Driving the ATV onto a Shift transmission to low range during loading of the ATV pickup or tall trailer in to prevent belt burning high range Starting out going up a When starting out on an incline use low range or dis steep incline mount the ATV after first applying the park brake and perform the K turn as described on page 63 Driving at low RPM or Drive at a higher speed or use low range more frequently low ground speed at The use of low range is highly recommended for cooler approximately 3 7 MPH PVT operating temperatures and longer component life Insufficient warm up of Warm the engine at least 5 minutes With the transmission ATVs exposed to low am in neutral advance the throttle to about 1 8 throttle in bient temperatures short bursts 5 to 7
27. set aside for reassembly 2 Remove the lamp 3 and replace it with a new lamp 3 Test the taillight brakelight to see that it s working 4 Reinstall the gasket and lens cover 100 MAINTENANCE AND LUBRICATION Spark Plugs Use BKRSE spark plugs for the Sportsman 400 and 500 Use RC7YC spark plugs for the Sportsman 600 and 700 Proper electrode gap is 035 90 mm Spark plug torque is 18 ft lbs 24 Nm CAUTION Using non recommended spark plugs can result in serious engine damage Always use Polaris recommended spark plugs Spark plug condition is indicative of engine operation The spark plug firing end condition should be read after the engine has been warmed up and the vehicle has been driven at higher speeds Immediately check the spark plug for correct color AWARNING A hot exhaust system and engine can cause serious burns Wear protective gloves when removing a spark plug for inspection 1 Normal The normal insulator tip is gray tan or light brown There will be few combustion deposits The electrodes are not burned or eroded This indicates the proper type and heat range for the engine and the service NOTE The tip should not be white A white insulator tip indicates overheating caused by use of an improper spark plug or incorrect carburetion adjustments 2 Wet Fouled The wet fouled insulator tip is black A damp oil film covers the firing end There may be a carbon layer over the entire
28. steady speed when climbing a hill If all forward speed is lost Keep your weight uphill Apply the brakes Lock the parking brake when fully stopped If the ATV begins rolling backwards Keep weight uphill Never apply engine power Never apply the rear brake while rolling backwards Apply the single lever brake gradually When fully stopped apply the rear brake as well and then lock the parking brake Dismount on uphill side or to either side if ATV is pointed straight uphill Turn the ATV around and remount following the procedure described in the owner s manual See page 63 30 SAFETY Operator Safety 4 WARNING POTENTIAL HAZARD Improperly operating over obstacles WHAT CAN HAPPEN Operating over obstacles could cause loss of control or overturn HOW TO AVOID THE HAZARD Before operating in a new area check for obstacles Avoid operating over large obstacles such as rocks and fallen trees when possible If unavoidable use extreme caution and always follow proper procedures as outlined in the owner s manual 4 WARNING POTENTIAL HAZARD Skidding or sliding WHAT CAN HAPPEN Skidding or sliding can cause loss of control If the tires regain traction unexpectedly the ATV could overturn HOW TO AVOID THE HAZARD On slippery surfaces such as ice travel slowly and use extra caution to reduce the chance of skidding or sliding out of control 31 SAFETY Operator Safety 4 WARNING
29. the original registration and received the customer copy please contact your dealer immediately NO WARRANTY COVERAGE WILL BE ALLOWED UNLESS YOUR ATV IS REGISTERED WITH POLARIS Initial dealer preparation and set up of your ATV is very important in ensuring trouble free operation Purchasing a machine in the crate or without proper dealer set up will void your warranty coverage 130 WARRANTY WARRANTY COVERAGE AND EXCLUSIONS LIMITATIONS OF WARRANTIES AND REMEDIES The Polaris limited warranty excludes any failures that are not caused by a defect in material or workmanship This warranty does not cover accidental damage normal wear and tear abuse or improper handling This warranty also does not cover any ATV that has been altered structurally modified neglected improperly maintained used for racing or used for purposes other than for which it was manufactured or for any damages which occur during trailer transit or as a result of unauthorized service or the use of unauthorized parts In addition this warranty does not cover physical damage to paint or finish stress cracks tearing or puncturing of upholstery material corrosion or defects in parts components or the ATV due to fire explosions or any other cause beyond Polaris control This warranty does not cover the use of unauthorized lubricants chemicals or fuels that are not compatible with the ATV The exclusive remedy for breach of this warranty shall be at Polaris
30. times The belt will become more flex ible and prevent belt burning Slow and easy clutch en Use the throttle quickly and effectively for efficient enga gagement gement Towing pushing at low Use low range only RPM low ground speed Utility use plowing snow Use low range only dirt etc Stuck in mud or snow Shift the transmission to low range and carefully use fast aggressive throttle application to engage clutch WARNING Excessive throttle may cause loss of control and vehicle overturn Climbing over large ob Shift the transmission to low range and carefully use fast jects from a stopped posi brief aggressive throttle application to engage clutch tion WARNING Excessive throttle may cause loss of control and vehicle overturn Belt slippage from water Shift the transmission to neutral Using the throttle vary or snow ingestion into the the engine RPM from idle to full throttle Repeat several PVT system times as required During this procedure the throttle should not be held at the full position for more than 10 seconds Clutch seals should be inspected for damage if repeated leaking occurs Clutch malfunction Contact your Polaris dealer for inspection of clutch com ponents Poor engine performance Check for fouled plugs or foreign material in gas tank fuel lines or carburetor Contact your dealer for service 117 TROUBLESHOOTING Contact your Polaris dealer for service if you re u
31. 2 Engine coolant Check for proper level at the recovery bottle 52 OPERATION Starting the Engine Starting a Cold Engine AWARNING Engine exhaust contains poisonous carbon monoxide and can cause loss of consciousness resulting in severe injury or death Never run an engine in an enclosed area 1 Place the transmission in neutral or PARK if equipped and lock the parking brake 2 Turn the fuel tank valve on 3 Sit on the vehicle and pull the choke knob out until it stops 1 NOTE The variable choke is fully on when the knob is pulled completely out The choke is off when the knob is pushed completely in The choke can be adjusted gradually depending on how much choke is needed for starting Be sure the choke is off during operation as excess fuel washing into the engine oil will increase wear on engine components 4 Turn the engine stop switch to RUN NOTE Do not press the throttle while starting the engine 5 Turn the ignition key past the ON position to engage the starter Activate the starter for a maximum of five seconds releasing the key when the vehicle starts If the engine does not start release the starter and wait five seconds Activate the starter for another five seconds if necessary Repeat this procedure until the engine starts 6 Ifthe engine slows or stops position the choke knob half way in to allow proper engine warm up 7 Vary the engine RPM slightly with the throttle to aid in warm u
32. AND LUBRICATION Transmission Oil 600 700 The transmission oil level should be checked every six months or 1000 miles 1600 km whichever comes first Transmission oil should be changed annually We recommend the use of Polaris Premium Synthetic Gearcase Lubricant See page 121 for the part numbers of Polaris products On the Sportsman 600 and 700 the transmission oil fill plug 1 is located on the right side of the ATV behind the footwell Oil Check 1 To access the fill plug remove the four screws on the footwell and gently pull outward to remove the footwell 2 Remove the fill plug and check the oil level The oil should be maintained 1 5 8 from the top of the fill plug hole Oil Change 1 Remove the four screws on the footwell and gently pull outward to remove the footwell 2 Remove the transmission drain plug 2 which is located on the bottom left hand side Drain the oil into a drain pan and dispose of properly 3 Clean and reinstall the drain plug Torque to 14 ft Ibs 19 Nm 4 Remove the fill plug and add 13 5 oz 399 ml of the recommended transmission oil to bring the level to the proper level 1 5 8 from the top of the fill plug hole 5 Replace the fill plug and check for leaks 6 Reinstall the footwell and screws 85 MAINTENANCE AND LUBRICATION Front Gearcase Oil 600 700 The front gearcase lubricant level should be checked every six months or 1000 miles 1600 km which
33. ARNING GF enna OD POTENTIAL HAZARD Operating this ATV on public streets roads or highways WHAT CAN HAPPEN The ATV could collide with another vehicle HOW TO AVOID THE HAZARD Never operate the ATV on any public street road or highway including dirt and gravel roads In many states it s illegal to operate ATVs on public streets roads and highways 19 SAFETY Operator Safety 20 4 WARNING POTENTIAL HAZARD Operating this ATV without wearing an approved helmet eye protection and protective clothing WHAT CAN HAPPEN Operating an ATV without an approved helmet increases the risk of a severe head injury or death in the event of an accident Operating without eye protection could result in an accident and could increase the chance of a severe injury in the event of an accident HOW TO AVOID THE HAZARD Always wear an approved helmet that fits properly Always wear eye protection goggles or face shield gloves boots long sleeved shirt or jacket and long pants SAFETY Operator Safety 4 WARNING POTENTIAL HAZARD Operating the ATV after consuming alcohol or drugs WHAT CAN HAPPEN Consumption of alcohol and or drugs could seriously affect operator judgment Reaction time may be slower and operator balance and perception could be affected Consuming alcohol and or drugs before or while operating an ATV could result in an accident causing severe injury or death HOW TO AVOID THE HAZARD N
34. Always use original equipment size and type when replacing tires Make sure the wheels are installed properly Always replace tires when the tread depth measures 1 8 3 cm or less Tire Tread Depth Always replace tires when tread depth is worn to 1 8 3 cm or less See illustration Wheel Removal 1 94 1 8 3 cm Stop the engine place the transmission in gear or in PARK if equipped and lock the parking brake Loosen the wheel nuts slightly Elevate the side of the vehicle by placing a suitable stand under the footrest frame Remove the wheel nuts and remove the wheel MAINTENANCE AND LUBRICATION Wheel Installation 1 Place the transmission in gear or in PARK if equipped and lock the parking brake 2 Place the wheel on the wheel hub with the valve stem toward the outside and rotation arrows on the tire pointing toward forward rotation 3 Install the wheel nuts and finger tighten 4 Lower the vehicle to the ground 5 Torque the wheel nuts according to the wheel nut torque specifications chart NOTE All nuts that have a cotter pin installed must be serviced by an authorized Polaris dealer Wheel Nut Torque Specifications Check the wheel nut torques occasionally and when they ve been loosened for maintenance service Sportsman 400 500 Sportsman 600 700 Front 3 8 20 ft Ibs 27 Nm 30 ft Ibs 41 Nm Rear 3 8 20 ft Ibs 27 Nm 30 ft Ibs 41 Nm
35. Below 5 C 5 C and above Meters 0 1800 157 5 Feet 0 6000 1800 3700 6000 12000 Altitude Shift Drive Clutch Driven Clutch Helix Weight Spring Spring Meters 0 1800 10 WH Blue Green White Yellow EBS Feet 0 6000 PN 5630710 PN 7041157 PN 7041635 PN 5131674 1800 3700 10 RH Blue Green White Yellow EBS 6000 12000 PN 5630709 PN 7041157 PN 7041635 PN 5131674 EBS models require no helix spring adjustment 125 SPECIFICATIONS SPORTSMAN 600 tongue weight not to exceed 200 lbs 90 7 kg Engine EHO59OLE021 Displacement 597 Bore x Stroke 76 5 x 65 Main Jet 155 Ignition System CDI Lubrication System 126 SPECIFICATIONS SPORTSMAN 600 Shift Type Side Lever High Low Neutral Reverse Park Gear Reduction Low 7 5 1 Gear Reduction Reverse 5 11 1 Gear Reduction High 3 09 1 Drive Ratio Front 3 82 1 Drive Ratio Final 3 10 1 Tire Size Front 25x8 12 Tire Size Rear 25x 11 12 Front Brake Hydraulic Disc Rear Brake Hydraulic Parking Brake Hydraulic lock all wheel Headlight watts 1 Single Beam on Handlebar 50 2 Single Beam on Grill 27 Taillights watts 8 26 Brake Light watts 26 9 Instrument Cluster LCD Jetting and Clutching Charts Sportsman 600 Altitude AMBIENT Below 40 F 40 F and above TEMPERATURE Below 5 C 5 C and above Meters 0 1800 Feet 0 6000 1800 3700 6000 12000 Altitude Shift Drive Clutch Driven Helix Weight Spring Clutch
36. CAN HAPPEN Severe injury and or death could occur if a child under the minimum age recommendation operates an ATV Even though a child may be within the recommended age group for operating some ATVs he she may not have the skills abilities or judgment needed to operate an ATV safely and could be susceptible to accident or injury HOW TO AVOID THE HAZARD No one under the age of 16 should operate a Polaris ATV SAFETY Operator Safety A WARNING POTENTIAL HAZARD Carrying a passenger on an ATV WHAT CAN HAPPEN Carrying a passenger greatly reduces the operator s ability to balance and control the ATV which could cause an accident and injury to the operator and or passenger HOW TO AVOID THE HAZARD Never carry a passenger The purpose of the long seat is to allow the operator to shift position as needed during operation It is not intended for carrying passengers 17 SAFETY Operator Safety 4 WARNING eos Lm Loan 7 x 3 i lt gt POTENTIAL HAZARD Operating an ATV on paved surfaces including sidewalks paths parking lots and driveways WHAT CAN HAPPEN ATV tires are designed for off road use Operating on paved surfaces may adversely affect the handling of the ATV and could result in loss of control accident and or injury HOW TO AVOID THE HAZARD Avoid operating the ATV on pavement If it s unavoidable travel slowly and avoid sudden turns or stops 18 SAFETY Operator Safety 4 W
37. G 117 120 Turning Around ona Hill 63 U USES Approved Spark Arrestor 68 V VEHICLE IDENTIFICATION NUMBERS 04 4 Vehicle Immersion 102 Ww WARRANTY 130 132 WELCOME 00005 3 Wheel Installation 95 Wheel Nut Torque Specifications 95 Wheel Removal 94 AWARNING Improper vehicle use can result in SEVERE INJURY or DEATH ALWAYS USE NEVER USE NEVER CARRY NEVER USE AN APPROVED ON PUBLIC PASSENGERS WITH DRUGS HELMET AND ROADS OR ALCOHOL PROTECTIVE GEAR NEVER e Operate without proper training or instruction Operate on public roads A collision can occur with another vehicle e Operate at speeds too fast for your skills or the conditions e Use ALCOHOL or DRUGS before or while operating this vehicle e Carry Passengers ALWAYS e Avoid paved surfaces which may adversely affect handling and control e Use proper RIDING TECHNIQUES to avoid vehicle overturns on hills and rough terrain and in turns e Wear eye protection helmet and protective apparel READ OWNER S MANUAL FOLLOW ALL INSTRUCTIONS AND WARNINGS Part No 9918540 Rev 04 gt POLARIS PRINTED IN THE USA The Way Out
38. HOW TO AVOID THE HAZARD Never operate the ATV on a frozen body of water If you re confident that the ice is thick enough and sound enough to support the machine and its operator as well as the force created by a moving vehicle exercise extreme caution SAFETY Operator Safety AWARNING Operating a damaged ATV can result in an accident with serious injury or death After any overturn or accident have a qualified service dealer inspect the entire machine for possible damage including but not limited to brakes throttle and steering systems AWARNING Safe operation of this rider active vehicle requires good judgement and physical skills Persons with cognitive or physical disabilities who operate this vehicle have an increased risk of overturn and loss of control which could result in severe injury or death CAUTION Exposure to the hot components could result in a fire Always keep combustible materials away from the exhaust system 35 CONTROLS Engine Electrical Switches AWARNING Activating the override switch while the throttle is open can cause loss of control resulting in severe injury or death Do not activate the override switch while the throttle is open Mode Reverse Override Switch 1 This vehicle is equipped with a reverse speed limiter system To gain additional power while backing depress the override switch NOTE The override switch also allows activation of All Wheel Drive AWD
39. If you scroll past the intended number hold the button down until the count turns over to 0 You can then reset the number If the service interval is enabled on your ATV and you wish to turn it off toggle to the service interval mode Press and hold the mode button for approximately 7 seconds until the word OFF appears in the Rider Information Center Screen 6 Miles Kilometers toggle The display in the tripmeter and odometer can be changed to display either kilometers or miles The current display mode will be shown as KM or MP To change hold in the mode button until the letters flash then press and release the button once When the display stops flashing the mode has been set 49 OPERATION Fuel Safety 50 AWARNING Gasoline is highly flammable and explosive under certain conditions e Always exercise extreme caution whenever handling gasoline e Always refuel with the engine stopped and outdoors or ina well ventilated area e Do not smoke or allow open flames or sparks in or near the area where refueling is performed or where gasoline is stored e Do not overfill the tank Do not fill the tank neck e If gasoline spills on your skin or clothing immediately wash it off with soap and water and change clothing e Never start the engine or let it run in an enclosed area Engine exhaust fumes are poisonous and can cause loss of con sciousness or death in a short time e Turn the fuel valve off whenever the ATV i
40. ON Operation of your vehicle without a breather filter can cause engine damage Always reinstall the breather filter after removing for service MAINTENANCE AND LUBRICATION Lights When servicing a halogen lamp don t touch the lamp with bare fingers Oil from your skin leaves a residue causing a hot spot that will shorten the life of the lamp AWARNING Poor lighting while driving can result in severe injury or death Headlight and taillight lenses become dirty during normal operation Wash the headlights frequently to maintain lighting quality Hot components can cause serious burns to skin Do not service the headlamps until they ve cooled sufficiently Headlight Lamp Replacement 1 Remove the two screws on the lower front corners of the headlight pod 2 Using a small flat blade screwdriver push in on the lock tab through the two small openings at the front of the headlight pod 3 Lift the pod slightly while depressing the tabs 4 Remove the screw in the back of the headlight pod 5 Lift the pod cover and disconnect the speedometer harnesses from the speedometer Unplug the indicator light harness and remove the pod cover 6 Unplug the headlamp from the wiring harness Be sure to pull on the connector not on the wiring 7 Remove the boot and locking collar from the back of the lamp housing 8 Grasp the base of the lamp and lift it out 9 Reverse the previous steps to replace the lamp and reassemble the
41. TV has an auxiliary brake 1 for added safety It s located on the inside of the right floor board and is operated by the right foot The auxiliary brake serves as a backup to the main brake system if the main system becomes inoperative If the rear wheels slide while using the auxiliary brake reduce brake pedal pressure to brake the rear wheels without skidding Brake Fluid Level Check the brake fluid level frequently for the auxiliary brake system The reservoir is located under the seat or near the auxiliary brake Maintain the fluid level between the maximum and minimum marks 41 CONTROLS Choke The choke assists in starting a cold engine Refer to the engine starting procedure on page 53 for correct choke and throttle settings during starting Fuel Valve The fuel valve 1 is located on the left side RES panel It has three positions OFF For vehicle storage and when transporting OFF ON For normal operation RES For reserve supply if main supply is ON exhausted NOTE There s about a 7 to 10 mile 11 2 to 16 km range on reserve gas Always refill the gas tank as soon as possible after using the main supply Always return the valve to the on position after refueling Fuel Tank The fuel tank filler cap 2 is located directly below the handlebar Use either leaded or unleaded gasoline with a minimum pump octane number of 87 R M 2 octane Fuel Filter The in line fuel filter should be repl
42. aced by your dealer after every 100 hours of operation or annually Do not attempt to clean the fuel filter 42 CONTROLS Automatic Transmission Gear Selector The transmission gear selector 1 is located on the right side of the vehicle Shift patterns vary depending on your model H High Gear L Low Gear N Neutral R Reverse P Park Sportsman 600 700 only To shift into HIGH or PARK on the Sportsman 600 or 700 you must first apply the auxiliary brake to activate the high park lock out mechanism When shifting out of HIGH or PARK it s not necessary to apply the brake Dy Zr I 400 500 600 700 CAUTION Shifting gears with the engine speed above idle or while the vehicle is moving could cause transmission damage To change gears stop the vehicle and with the engine idling move the lever to the desired gear Apply the auxiliary brake if shifting into HIGH or PARK on the Sportsman 600 or 700 Whenever the ATV is left unattended always place the transmission in first gear or in PARK if equipped and lock the parking brake Maintaining shift linkage adjustment is important to assure proper transmission function on the Sportsman 400 and 500 See your dealer if you experience any shifting problems Belt Life To extend belt life use low forward gear in heavy pulling situations and when operating at less than seven miles per hour for extended periods of time 43 FEATURES All Wheel Drive AWD System
43. adequate level see page 39 NOTE Under normal functioning the diaphragm extends into the reservoir as fluid level drops If the fluid level is low and the diaphragm is not extended a leak is likely and the diaphragm should be replaced Always fill the reservoir as needed whenever the cover is loosened or removed to ensure proper diaphragm operation Use Polaris DOT 3 brake fluid see page 121 2 Check the brake system for fluid leaks 3 Check the brakes for excessive travel or spongy feel 4 Check the friction pads for wear damage and looseness 5 Check the security and surface condition of the disc NOTE Pads should be changed when worn to 3 64 1 cm or about the thickness of a U S dime 3 64 1 cm 90 MAINTENANCE AND LUBRICATION Rear Brake The rear brake is a hydraulic disc brake and is activated by the same lever that activates the front brake system The rear brake system is self adjusting and requires no maintenance other than periodic checks of the pads for wear Pads should be changed when worn to 3 64 1 cm which is about the thickness of a U S dime Inspect the brake disc spline and pad wear surface for excessive wear Auxiliary Brake 3 64 1 cm Your auxiliary brake is intended to be used as a backup for the main brake system Should the main system fail the rear brake can be activated by depressing the foot pedal on the
44. ak In Period 51 Breather Filter 0 0 0 96 Cc Camber and Caster 114 Carburetor Idle RPM 115 Choke iei E ace cess ee 42 Cleaning occ e ete eee 110 113 Clutching Chart 400 123 Clutching Chart 500 125 Clutching Chart 600 127 Clutching Chart 700 129 Cold Weather Operation 54 CONTROLS vais ede oe ce eet 36 43 Coolant Level 00 88 Cooling System 88 Crankcase Emission Control System 68 D Diagnostic Mode 48 49 Driving in Reverse 66 Driving on Slippery Surfaces 59 Driving Over Obstacles 65 Driving Procedures 57 Driving Safely 57 67 Driving Through Water 64 INDEX E Electrical Switches 36 EMISSION CONTROL SYSTEMS 68 Engaging Front Gearcase 44 Engine Cooling System 89 Engine Stop Switch 36 Exhaust Emission Control System 68 Equipment Modifications 15 F FEATURES 935 cc tonsa anes een oa 44 49 Filter Systems 0 00 96 Front Gearcase Oil 400 500 84 Front Gearcase Oil 600 700 86 Front Wheel Hub Tightening 95 Fuel Filter ecco cioisstiaeccassgade 42 Ruel Satetyecs 7 hehe ea ee Ra hah 50 Fuel Tank 0 0 00 00 00 42 Fuel Valve 0 0 0 eee ee eee ee 42 G Gear Sele
45. ause loss of control or overturn HOW TO AVOID THE HAZARD Always follow proper procedures for traveling down hills as described in the owner s manual NOTE A special technique is required when braking while traveling downhill See page 62 Always check the terrain carefully before descending a hill Shift your weight backward Never travel down a hill at high speed Avoid traveling down a hill at an angle which would cause the vehicle to lean sharply to one side Travel straight down the hill when possible 28 SAFETY Operator Safety 4 WARNING POTENTIAL HAZARD Improperly crossing hills and turning on hills WHAT CAN HAPPEN Improperly crossing or turning as hills could cause loss of control or overturn HOW TO AVOID THE HAZARD Never attempt to turn the ATV around on any hill until you ve mastered the turning technique on level ground as described in the owner s manual See page 63 Use extra caution when turning on any hill Avoid crossing the side of a steep hill When crossing the side of a hill Always follow proper procedures as described in the owner s manual Avoid hills with excessively slippery or loose surfaces Shift your weight to the uphill side of the ATV 29 SAFETY Operator Safety 4 WARNING POTENTIAL HAZARD Stalling rolling backwards or improperly dismounting while climbing a hill WHAT CAN HAPPEN The vehicle could overturn HOW TO AVOID THE HAZARD Maintain
46. c throttle control malfunction Other mechanical failure Overheated engine Clean radiator screen and core Clean engine exterior See your Polaris dealer Engine Overheating Possible Cause Solution Debris lodged in screen Remove and clean the screen Pull on the top portion of the screen then remove the lower portion Plugged Radiator Use a garden hose to flush any debris from the radiator fins NOTE High pres sure washers can deform the radiator fins and reduce cooling efficiency 120 POLARIS PRODUCTS Part No Description Engine Lubricant 2870791 Fogging Oil 12 oz Aerosol 2871281 Engine Oil qt Premium 4 Synthetic OW 40 4 Cycle 2871844 Engine Oil gal Premium 4 Synthetic OW 40 4 Cycle aaria 287178 2871653 2872276 2870465 2871654 2872277 2871322 2871423 2871460 2871515 2871551 2871312 2871329 Dielectric Grease Nyogel 2871323 60 40 Coolant Gallon 2871534 60 40 Coolant Quart 121 SPECIFICATIONS SPORTSMAN 400 weight not to exceed 180 Ibs 81 6 kg Displacement 425 Driving System Type Dual sensing automatic PVT Polaris Variable Transmission 122 Shift Type Gear Reduction Low Gear Reduction Reverse Gear Reduction Forward Drive Ratio Front Drive Ratio Final Tire Front Tire Rear Front Brake Rear Brake Auxiliary Brake Parking Brake Front Suspension Rear Suspension Shock Adjustment Headlight Taillights Brakelight Instrument Clu
47. cause fuel to build in the exhaust resulting in engine popping and or engine damage 66 OPERATION Driving Safely Parking on an Incline Avoid parking on an incline if possible If it s unavoidable follow these precautions 1 2 3 4 Turn the engine off Place the transmission in low range or park if equipped Set the parking brake Always block the rear wheels on the downhill side as shown in the illustration Shut off the fuel supply 67 EMISSION CONTROL SYSTEMS Noise Emission Control System TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED U S Federal law prohibits the following acts or the causing thereof 1 the removal or rendering inoperative by any person other than for purposes of maintenance repair or replacement of any device or element of design incorporated into any new vehicle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use or 2 the use of the vehicle after such device or element of design has been removed or rendered inoperative by any person ACTS PRESUMED TO CONSTITUTE TAMPERING INCLUDE BUT ARE NOT LIMITED TO THE FOLLOWING 1 Removal alteration or the puncturing of the muffler or any engine component that conducts removal of engine exhaust gases 2 Removal alteration or the puncturing of any part of the engine air induction system 3 Replacement of any vehicle parts with parts not in compliance with federal r
48. ctor 43 H Handlebars 114 Hauling Cargo 55 56 Headlamp Removal Installation 100 Headlight Housing Replacement 99 Headlight Lamp Replacement 97 High Beam Adjustment 98 High Ranges sunean co eee hoes 104 Hour Meter 0040 47 l Instrument Cluster 45 49 J Jetting Clutching 400 123 Jetting Clutching 500 125 Jetting Clutching 600 127 Jetting Clutching 700 129 K KeU ee ae ee E e CAAO G Recs 63 L Light Switches 0 38 Tea ghts 2a o Macrae n aera ere 97 100 Low Range 004 104 Lubrication Guide 76 77 INDEX M Main Switch 00 36 MAINTENANCE AND LUBRICATION 69 113 Maintenance Record 74 Making Turns 0 58 Master Cylinder 39 N Noise Emission Control System 68 O Odometer hoe gis cab E E E 47 Qil Change och ieee E wet 80 Oil Change 400 500 80 81 Oil Change 600 700 82 ON Checks reak act sceeonee rere te 79 Oil Filter Change 80 OPERATION 50 67 Operator Safety 11 35 Override Switch 0 36 P Parking Brake 40 Parking on an Incline 67 Periodic Maintenance Schedule 69 73 POLARIS PRODUCTS 121 Pre Ride Inspection
49. d on the bottom of the gearcase 3 Drain the oil into a drain pan and dispose of properly 3 4 Clean and reinstall the drain plug Add 32 oz 948 ml of the recommended transmission oil to bring the level to the full mark on the fill plug dipstick Maintain the oil level in the safe range NOTE See page 121 for the part numbers of Polaris products 6 Reinstall the fill plug dipstick and check for leaks 83 MAINTENANCE AND LUBRICATION Front Gearcase Oil 400 500 The front gearcase lubricant level should be checked every six months or 1000 miles 1600 km whichever comes first Front gearcase oil should be changed annually Use Polaris Premium Synthetic Gearcase Lube or GLS 80 90 weight gear lube See page 121 for the part numbers of Polaris products Oil Check 1 Position the ATV on a level surface 2 Remove the fill plug 1 and view the lubricant level Lubricant should be kept level with the bottom of the fill plug threads 3 Add the recommended lubricant as needed to bring the oil to the proper level Oil Change 1 Position the vehicle on a level surface and remove the fill plug 2 Place a drain pan beneath the gearcase remove the gearcase drain plug and drain the oil 3 Clean and reinstall the drain plug Torque to 14 ft Ibs 19 Nm Add 4 ounces 120 ml of the recommended gearcase oil 5 Reinstall the fill plug and check for leaks 5 84 MAINTENANCE
50. disc type brakes that are ks activated by only one lever Always test brake lever travel and master cylinder fluid level before riding When squeezed the lever should feel firm Any sponginess would indicate a possible fluid leak or low master cylinder fluid level which must be corrected before riding Contact your dealer for proper diagnosis and repairs AWARNING Operating the ATV with a spongy brake lever can result in loss of braking which could cause an accident Never operate the ATV with a spongy feeling brake lever 38 CONTROLS Master Cylinder The brake fluid in the master 1 2 cylinder 1 which is located on the left handlebar should be checked before each ride The fluid level can be seen through an indicator window 2 on the top of the master cylinder This eye will appear dark when the fluid level is full When fluid needs to be added the eye will be clear NOTE When checking the fluid level the ATV must be on level ground with the handlebars straight If the fluid level is low add DOT 3 brake fluid only See page 121 for the part numbers of Polaris products f fle g5 AWARNING After opening a bottle of brake fluid always discard any unused portion Never store or use a partial bottle Brake fluid is hygroscopic meaning it rapidly absorbs moisture from the air The moisture causes the boiling temperature of the brake fluid to drop which can lead to early brake fade and the possibility o
51. dures when operating through water 1 Determine water depths and current before crossing 2 Choose a crossing ee where both banks have gradual inclines 3 Proceed slowly avoiding rocks and obstacles if possible 4 After crossing dry the brakes by applying light pressure to the lever until braking action is normal After running the vehicle in water it s critical to have it serviced as outlined in the maintenance chart See page 69 The following areas need special attention engine oil transmission oil front and rear gearcases and all grease fittings 4 CAUTION Major engine damage can result if the vehicle is not thoroughly inspected after operation in water Perform the services outlined in the maintenance chart If your vehicle becomes immersed or is operated in water that exceeds the footrest level take it to your dealer for service before starting the engine NOTE Avoid operating the vehicle through deep or fast flowing water If you cannot avoid water that exceeds the recommended maximum depth go slowly balance your weight carefully avoid sudden movements and maintain a slow and steady forward motion Do not make sudden turns or stops and do not make sudden throttle changes If your vehicle becomes immersed and it s impossible to take it to a dealer before starting it follow the steps described on page 102 Have the vehicle serviced by your dealer at the first opportunity 64 OPERATION
52. e Shift Drive Clutch Driven Helix Weight Spring Clutch Spring Meters 0 1800 20 56 Blue Green White Yellow EBS Feet 0 6000 PN 5631315 PN 7041157 PN 7041635 PN 5132751 1800 3700 20 54 Blue Green White Yellow EBS 6000 12000 PN 5631214 PN 7041157 PN 7041635 PN 5132751 EBS models require no helix spring adjustment 129 WARRANTY LIMITED WARRANTY Polaris Sales Inc 2100 Highway 55 Medina MN 55340 gives a SIX MONTH LIMITED WARRANTY on all components of the Polaris All Terrain Vehicle ATV against defects in material or workmanship Polaris also gives a one year limited warranty on the final drive chain for failure due to defects This warranty covers the parts and labor charges for repair or replacement of defective parts which are covered by this warranty This warranty begins on the date of purchase This warranty is transferrable to another consumer during the warranty period through a Polaris dealer REGISTRATION At the time of sale the Warranty Registration Form must be completed by your dealer and submitted to Polaris within ten days Upon receipt of this registration Polaris will record the registration for warranty THE PURCHASER MUST COMPLETE AN ATV SAFETY TRAINING COURSE PROVIDED BY THE DEALER IN ORDER TO HAVE VALID WARRANTY ON THE ATV No verification of registration will be sent to the purchaser as the copy of the Warranty Registration Form will be the warranty entitlement If you have not signed
53. e dish soap type cleaners only High pressure washers may force water past seals Stabilize the Fuel Fill the fuel tank Add Polaris Carbon Clean Fuel Treatment or Polaris Fuel Stabilizer Follow the instructions on the container for the recommended amount Carbon clean will also reduce the possibility of bacterial growth in the fuel system Allow 15 20 minutes of operation for the stabilizer to disperse through the fuel in the tank and carburetor Turn the fuel valve off and drain the carburetor bowl Oil and Filter Warm the engine and change the oil and filter Air Filter Air Box Inspect and clean or replace the pre cleaner and air filter Clean the air box and drain the sediment tube Breather Filter Inspect and clean or replace the breather filter Fluid Levels Inspect the following fluid levels and change if necessary front and rear gearcases transmission and brake fluid change every two years or as required if fluid looks dark or contaminated 111 MAINTENANCE AND LUBRICATION Cleaning and Storage Storage Tips Fog the Engine 1 Remove the spark plug and add 2 3 tablespoons of Premium 4 Synthetic 0W40 engine oil To access the plug hole use a section of clear 1 4 hose and a small plastic squeeze bottle filled with the pre measured amount of oil NOTE Do this carefully If you miss the plug hole oil will drain from the spark plug cavity into the hole at the front of the cylinder head and appear to be an oil
54. egulations 4 Lack of proper maintenance 4 CAUTION Exhaust system components are very hot during and after use of the vehicle Hot components can cause serious burns and fire Do not touch hot exhaust system components Use caution when traveling through tall grass especially dry grass USFS Approved Spark Arrestor Your Polaris ATV has a muffler that was tested and approved in accordance with the USFS Forest Service Standard 5100 1A Exhaust Emission Control System The exhaust emission control system is composed of efficient carburetor settings with an optimum ignition system Idle speed can be adjusted with the throttle stop screw The carburetor must be maintained at Polaris specifications to achieve optimal performance Crankcase Emission Control System This engine is equipped with a closed crankcase system It allows blow by gases back to the combustion chamber using the intake system It does not allow the blow by gases to enter the atmosphere 68 MAINTENANCE AND LUBRICATION Periodic Maintenance Schedule Careful periodic maintenance will help keep your vehicle in the safest most reliable condition Inspection adjustment and lubrication of important components are explained in the periodic maintenance schedule Use the instrument cluster s programmable service interval mode to help determine when maintenance service is due See page 49 for instructions Maintenance intervals are based upon average riding conditi
55. er eye protection A pair of goggles or a helmet face shield offer the best protection for your eyes They should be kept clean and be of shatterproof design bearing the markings z2 1 or VESC 8 3 Gloves Off road style gloves with knuckle pads are the best for comfort and protection 4 Boots The best footwear is a pair of strong over the calf boots with heels like moto cross boots 5 Clothing Always wear long sleeves and long pants to protect arms and legs Riding pants with kneepads and a jersey with shoulder pads provide the best protection 10 SAFETY Operator Safety AWARNING Failure to follow the warnings contained in this manual can result in severe injury or death A Polaris ATV is not a toy and can be hazardous to operate This vehicle handles differently than other vehicles such as motorcycles and cars A collision or rollover can occur quickly even during routine maneuvers like turning or driving on hills or over obstacles if you fail to take proper precautions Read and understand your owner s manual and all warnings before operating a Polaris ATV Age Restrictions This vehicle is an ADULT VEHICLE ONLY Operation is prohibited for anyone under 16 years of age Know Your Vehicle As the operator of the vehicle you are responsible for your personal safety the safety of others and the protection of our environment Read and understand your owner s manual which includes valuable informati
56. ever comes first Front gearcase oil should be changed annually We recommend the use of Polaris Premium Hub Drive Fluid See page 121 for the part numbers of Polaris products Oil Check 1 Position the ATV on a level surface 2 Remove the fill plug 1 and view the oil level Maintain the oil level even with the bottom of the fill plug hole 3 Add the recommended gearcase oil as needed Oil Change 1 Position the vehicle on a level surface and remove the fill plug 2 Place a drain pan beneath the gearcase remove the gearcase drain plug located on the bottom right hand side and drain the oil 3 Clean and reinstall the drain plug Torque to 14 ft Ibs 19 Nm 4 Add 5 ounces 150 ml of Polaris Premium Hub Drive Fluid 5 Reinstall the fill plug and check for leaks 86 MAINTENANCE AND LUBRICATION Rear Gearcase Oil 600 700 The rear gearcase lubricant level should be checked every six months or 1000 miles 1600 km whichever comes first Rear gearcase oil should be changed annually Use Polaris Premium Synthetic Gearcase Lube or GLS 80 90 weight gear lube NOTE See page 121 for the part numbers of Polaris products Oil Check 1 Position the ATV on a level surface 2 Remove the fill plug and inspect the oil level through the fill plug hole 1 Maintain the oil level even with the bottom of the fill plug hole 3 Add the recommended gearcase oil as needed Oil Change 1 Place a drain pan beneath the d
57. ever consume alcohol or drugs before or while operating an ATV 4 WARNING POTENTIAL HAZARD Operating the ATV at excessive speeds WHAT CAN HAPPEN Excessive speed increases the operator s chance of losing control of the ATV which can result in an accident causing severe injury or death HOW TO AVOID THE HAZARD Always operate the ATV at a speed that s proper for the terrain visibility and operating conditions and your experience 21 SAFETY Operator Safety 22 4 WARNING POTENTIAL HAZARD Attempting wheelies jumps and other stunts WHAT CAN HAPPEN Attempting stunts increases the chance of an accident including an overturn HOW TO AVOID THE HAZARD Never attempt wheelies jumps or other stunts Avoid exhibition driving SAFETY Operator Safety 4 WARNING POTENTIAL HAZARD Failure to inspect the ATV before operating Failure to properly maintain the ATV WHAT CAN HAPPEN Poor maintenance increases the possibility of an accident or equipment damage HOW TO AVOID THE HAZARD Always inspect your ATV before each use to make sure it s in safe operating condition Always follow the inspection and maintenance procedures and schedules described in the owner s manual 4 WARNING POTENTIAL HAZARD Removing hands from the handlebars or feet from the footrests during operation WHAT CAN HAPPEN Removing even one hand or foot can reduce ability to control the vehicle or could cause loss of ba
58. f accident or severe injury 39 CONTROLS Parking Brake AWARNING Operating the ATV while the parking brake is engaged could result in an accident and serious injury or death Always check to be sure the parking brake is disengaged before operating Setting the Parking Brake 1 2 Place the transmission in first gear or in PARK if equipped Squeeze and release the brake lever 1 two or three times then squeeze and hold Push the park brake lock 2 forward to engage the brake Release the brake lever To release the parking brake lock squeeze and release the brake lever It will return to its unlocked position Important Safeguards The parking brake may relax if left on for a long period of time Al ways block the wheels to prevent rolling Always block the wheels on the downhill side of the ATV if leaving it parked on a hill Another option is to park the ATV in a sidehill position Never depend on the parking brake alone if the ATV is parked on a hill Always block the wheels to prevent rolling 40 CONTROLS Auxiliary Brake AWARNING Aggressively applying the auxiliary brake when backing down a hill may cause rear tipover which could result in serious injury or death Use caution when applying the auxiliary brake Do not aggressively apply the auxiliary brake when going forward The rear wheels may skid and slide sideways causing loss of control and serious injury or death Your Polaris A
59. f fresh engine oil Check to make sure the o ring is in good condition Install the new filter and turn by hand until the filter gasket contacts the sealing surface then turn and additional 1 2 turn Remove the dipstick and fill the sump with two quarts 1 9 1 of recommended oil Place the gear selector in PARK and set the parking brake Start the engine and let it idle for one to two minutes Stop the engine and inspect for leaks Re check the oil level on the dipstick and add oil as necessary to bring the level to the upper mark on the dipstick Dispose of used filter and oil properly MAINTENANCE AND LUBRICATION Transmission Oil 400 500 The transmission oil level should be checked every six months or 1000 miles 1600 km whichever comes first Transmission oil should be changed annually We recommend the use of Polaris Premium Synthetic Gearcase Lubricant See page 121 for the part numbers of Polaris products Oil Check On the Sportsman 400 and 500 the transmission oil dipstick 1 is located near the rear brake disc on the right side of the ATV 1 Position the ATV on a level surface Remove the fill plug dipstick and wipe it clean 2 Reinstall the dipstick completely then remove it and check the O level Add the recommended oil as needed to bring the level into the safe operating range 2 2 Oil Change e 1 Remove the fill plug dipstick 2 Remove the transmission 4 drain plug 3 It s locate
60. g downhill and for braking on hills Check the terrain carefully before you start down a hill Shift your weight backward Never go down a hill at high speed Avoid going down a hill at an angle which would cause the vehicle to lean sharply to one side Travel straight down the hill when pos sible Always follow proper procedures for crossing the side of a hill Avoid hills with excessively slippery or loose surfaces Shift your weight to the uphill side of the ATV Never attempt to turn the ATV around on any hill until you ve mastered on level ground the turn ing technique outlined in this manual Avoid crossing the side of a steep hill when possible Always use proper procedures if you stall or roll backwards while climbing a hill To avoid stalling maintain a steady speed when climbing a hill If you stall or roll backwards follow the special procedure for braking described in this manual Always dismount on the uphill side or to either side if the ATV is pointed straight uphill Turn the ATV around and remount following the procedure described in this manual Always check for obstacles before operating in a new area Never attempt to operate over large obstacles such as rocks or fallen trees Always follow proper procedures when operating over obstacles as described in this manual Always be careful of skidding or sliding On slippery surfaces like ice travel slowly and use extra caution to reduce the chance of skid ding or slidin
61. g out of control Avoid operating the ATV through deep or fast flowing water If it s unavoidable travel slowly balance your weight carefully avoid sud den movements and maintain a slow and steady forward motion Do not make sudden turns or stops and do not make sudden throttle changes 14 SAFETY Operator Safety e Wet brakes may have reduced stopping ability Test the brakes after leaving water If necessary apply them lightly several times to allow friction to dry out the pads e Always check for obstacles or people behind the ATV before operat ing in reverse When it s safe to proceed in reverse move slowly and avoid turning at sharp angles e Always use the size and type of tires specified for your ATV and always maintain proper tire pressure e Never modify an ATV through improper installation or use of acces sories e Never exceed the stated load capacity for your ATV Cargo must be properly distributed and securely attached Reduce speed and follow the instructions in this manual for carrying cargo or towing Allow a greater distance for braking FOR MORE INFORMATION ABOUT ATV SAFETY call the Con sumer Product Safety Commission at 1 800 638 2772 or call Polaris at 1 800 342 3764 Equipment Modifications We are concerned for the safety of our customers and for the general public Therefore we strongly recommend that consumers do not install on a Polaris ATV any equipment that may increase the speed or power
62. he rear too much heel Net throttle is ap wheels are spinning plied Loss of This may cause severe k THIS VEHICLE IS AN ALL TERRAIN VEHICLE AND IS NOT control or for drive shaft and clutch INTENDED FOR USE ON PUBLIC ROADS ward flipover damage may result es See your Owner s CE VEHICULE EST UN VEHICULE TOUT TERRAIN pecially in Manual QUI NEST PAS DESTINE A ETRE UTILISE SUR LES AWD See Own CHEMINS PUBLICS er s Manual 7079780 7079604 7078470 Canadian Certification Decal TRAILER MAX WEIGHT 1225 LBS 557 KG ON LEVEL GROUND 850 LBS 386 KG UP TO 15 GRADE HITCH MAX VERTICAL WEIGHT 120 LBS 55KG 7170911 Sportsman 400 500 TRAILER MAX WEIGHT 1500 LBS 682 KG ON LEVEL GROUND 850 LBS 386 KG UP TO 15 GRADE HITCH MAX VERTICAL WEIGHT 150 LBS 68KG 7170509 Sportsman 600 700 SAFETY Safe Riding Gear Always wear clothing suited to the type of riding ATV riding requires special protective clothing for comfort and to reduce the chance of injury 1 Helmet Your helmet is the most important piece of protective gear for safe riding A helmet can prevent a severe head injury Select an approved helmet that meets or exceeds your state s safety standards and bears either the Department of Transportation DOT label the American National Standards Institute label ANSI z90 1 or the Snell Memorial Foundation label 2 Eye Protection Do not depend on sunglasses for prop
63. ibution 1 3 front 2 3 rear is best For stability on rough or hilly terrain reduce speed and cargo Do not block headlight Be careful if load extends over the side of the rack Read Owner s Manual for more detailed loading information 4 WARNING NEVER ride as a passenger Passengers can cause a loss of control resulting in SEVERE INJURY or DEATH 7079084 7077920 SAFETY Safety Decals and Locations A WARNING Moving parts hazard under belt clutch guard To prevent serious injury do not operate vehicle with guard removed Do not modify engine or clutch Doing so can cause part failure possible imbalance and excessive engine RPM which can result in serious injury or death 7078689 NO STEP 4 WARNING DO NOT TOW FROM RACK OR BUMPER Vehicle damage or tipover may result causing severe injury or death Tow only from tow hooks or hitch Max Rack Loads Front 90 Ibs 41 kg Rear 180 Ibs 82 kg 7170021 Sportsman 400 500 A WARNING DO NOT TOW FROM RACK OR BUMPER Vehicle damage or tipover may result causing severe injury or death Tow only from tow hooks or hitch Max Rack Loads Front 100 Ibs 45 kg Rear 200 Ibs 91 kg 7170912 Sportsman 600 700 SAFETY Safety Decals and Locations 4 WARNING ALL WHEEL Pushing reverse DRIVE MANUFACTURED override button BY POLARIS IND INC may cause SWITCH sudden in creases Ini pOw Do not push switch to er and traction if engage AWD if t
64. ine when turned fully to the left or right 4 Torque the front two bolts to 10 12 ft lbs 14 17 Nm then torque the rear two bolts A gap of up to 1 8 will remain at the rear bolts 114 ADJUSTMENTS Carburetor Idle RPM If the engine idle speed is not satisfactory and all other conditions are favorable the carburetor can be adjusted 1 Warm up the engine by running the vehicle for approximately five minutes 2 Place the transmission in gear with the parking brake applied 3 Adjust the carburetor idle screw 1 either in or out until the desired idle RPM is reached Turning the screw in clockwise will raise RPM Turning the screw out counterclockwise will lower RPM IMPORTANT Your Polaris ATV is calibrated at the factory for optimal performance at altitudes ranging from zero to 6 000 feet 1800 m and temperatures of 40 degrees F 4 degrees C or higher Above 6000 feet 1800 m the engine air fuel mixture becomes overly rich and the engine loses approximately 3 of its power for each 1000 foot 304 8 m increase in elevation Although this power cannot be regained adjustments to the carburetor and drive system can be made to allow more efficient operation Optional jets available from your Polaris dealer are required for operation above 6 000 feet and temperatures below 40 degrees F 4 degrees C NOTE Continuous operation of the engine without proper jetting when required can cause poor performance
65. is dealer to purchase a replacement Replacement safety decals are provided by Polaris at no charge The part number is printed on the decal 4 WARNING Improper ATV use can result in SEVERE INJURY or DEATH DOSE ALWAYS USE NEVER USE NEVERCARRY NEVER USE AN APPROVED ONPUBLIC PASSENGERS WITH DRUGS HELMET AND ROADS OR ALCOHOL PROTECTIVE GEAR NEVER operate without proper training or instruction at speeds too fast for your skills or the conditions on public roads a collision can occur with another vehicle with a passenger passengers affect balance and steering and increase risk of losing control ALWAYS e use proper riding techniques to avoid vehicle overturns on hills and rough terrain and in turns avoid paved surfaces pavement may seriously affect handling and control LOCATE AND READ OWNER S MANUAL FOLLOW ALL INSTRUCTIONS AND WARNINGS IF OWNER S MANUAL IS MISSING CONTACT A POLARIS DEALER FOR A REPLACEMENT 1997 2000 7079083 AWARNING eNever operate this vehicle on HILLS steeper than 25 degrees 725 To prevent flipover on hilly terrain when going up or down use throttle and brakes gradually eREVERSE operation can be dangerous even at low speeds Steering becomes difficult To prevent flipover avoid sudden braking or sharp turns eUse OVERRIDE for reverse speed limiter with caution To prevent loss 4 WARNING of control never activate override button with o
66. its which provide quicker warm ups and easier starting in colder weather 54 OPERATION Hauling Cargo 1 3 Your ATV has been designed to carry or tow a certain amount of load Always read and understand the load distribution warning labels on the vehicle and never exceed the weight capacities outlined in the specifications section of the owner s manual and on the safety decals Cargo weight should be evenly distributed 1 3 on the front rack and 2 3 on the rear rack and mounted as low as possible When operating over rough or hilly terrain reduce speed and cargo weight to maintain stable driving conditions Do not obstruct the headlight beam with cargo Belt Life Use low forward gear when hauling or towing heavy cargo to extend belt life 55 OPERATION Hauling Cargo AWARNING Hauling cargo improperly can alter vehicle handling and may cause loss of control or brake instability and result in serious injury or death Always follow these precautions when hauling cargo e REDUCE SPEED AND ALLOW GREATER DISTANCES FOR BRAKING WHEN HAULING CARGO e CARGO WEIGHT DISTRIBUTION should be 1 3 on the front rack and 2 3 on the rear rack When operating over rough or hilly terrain reduce speed and cargo to maintain stable driving conditions Carrying loads on one rack only increases the possibility of vehicle overturn e CARRY LOADS AS LOW ON THE RACKS AS POSSIBLE Carrying loads high on the racks raises the center of gravity
67. ks at tank hours cap lines fuel valve filter pump and carburetor re place lines every two years m Fuel filter 100 hrs 12 months Replace annually Radiator 100 hrs 12 months Inspect clean external sur face Cooling system 100 hrs 12 months Inspect hoses Spark arrestor 100 hrs 12 months Clutches drive and 100 hrs 12 months Inspect clean driven m Brake fluid 200 hrs 24 months Change every two years Fi Front wheel bear 300 hrs Inspect replace as needed ings Toe adjustment As required Periodic inspection adjust when parts are replaced B Headlight aim As required Adjust as needed 73 MAINTENANCE AND LUBRICATION Periodic Maintenance Record Use the following chart to record periodic maintenance Maintenance Servicing Servicing Interval Date Dealer Performed or Person a a a as 74 NOTES 75 MAINTENANCE AND LUBRICATION Lubrication Guide NOTE Hours in the frequency column are based on 10 mph average If service is due at 20 hours the equivalent odometer reading would be 200 miles Perform all services at whichever reading is reached first Lubrication Guide Key p gt More often under severe use such as wet or dusty conditions Polaris Premium All Season Grease or grease conforming to NLGI No 2 such as Conoco Superlube M or Mobilegrease Special Use Polaris Premium U Joint Lube every 500 miles before long periods of storage or after pres
68. lance and ejection from the ATV If the operator s foot is not firmly planted on the footrest it could come into contact with the rear wheels and lead to accident or injury HOW TO AVOID THE HAZARD Always keep both hands on the handlebars and both feet on the footrests of the ATV during operation 23 SAFETY Operator Safety 4 WARNING POTENTIAL HAZARD Failure to use extra caution when operating the ATV on unfamiliar terrain WHAT CAN HAPPEN Unfamiliar terrain may contain hidden rocks bumps or holes that could cause loss of control or overturn HOW TO AVOID THE HAZARD Travel slowly and use extra caution when operating on unfamiliar terrain Always be alert to changing terrain conditions 24 SAFETY Operator Safety 4 WARNING POTENTIAL HAZARD Failure to use extra caution when operating on excessively rough slippery or loose terrain WHAT CAN HAPPEN Operating on excessively rough slippery or loose terrain could cause loss of traction or loss of control which could result in an accident or overturn HOW TO AVOID THE HAZARD Do not operate on excessively rough slippery or loose terrain until you ve learned and practiced the skills necessary to control the ATV on such terrain Always use extra caution on rough slippery or loose terrain 25 SAFETY Operator Safety 4 WARNING POTENTIAL HAZARD Turning improperly WHAT CAN HAPPEN Improper turns could cause loss of control and
69. leak 2 Reinstall the spark plug Torque to 18 ft Ibs 24 Nm 3 Apply dielectric grease to the inside of the spark plug cap and install the cap onto the plug 4 Turn the engine over several times Oil will be forced in and around the piston rings and ring lands coating the cylinder with a protective film of fresh oil Alternative to Using Fogging Oil If you choose not to use Polaris Fogging Oil perform the following procedure 1 Treat the fuel system with Polaris Carbon Clean following the instructions on the can Run the engine for several minutes so the Carbon Clean reaches the carburetor Turn the engine off 2 Support the front end of the machine so the engine is level or tilted slightly rearward 3 Remove the spark plug Rotate the piston to BDC and pour approximately two ounces of recommended oil into the cylinder 4 Reinstall the spark plug and torque to 18 ft Ibs 24 Nm 5 Apply dielectric grease to the inside of the spark plug cap and install the cap onto the plug 6 Turn the engine over several times to ensure coverage of piston rings cylinder walls and crankshaft bearings 7 If Polaris fuel system additive is not used fuel tank fuel lines and carburetor should be completely drained of gasoline To eliminate any fuel remaining in the carburetor run the engine until it stops Inspect and Lubricate Inspect all cables and lubricate Follow lubrication guidelines in the Maintenance Section of the se
70. low the recovery system to function properly Contact your dealer for the correct replacement part NOTE To ensure that the coolant maintains its ability to protect the engine we recommend that the system be completely drained every two years and a fresh mixture of antifreeze and water added Polaris recommends the use of Polaris Premium 60 40 anti freeze coolant or a 50 50 mixture of high quality aluminum compatible anti freeze coolant and distilled water Polaris Premium 60 40 is already premixed and ready to use Do not dilute with water See page 121 for the part numbers of Polaris products NOTE Always follow the manufacturer s mixing recommendations for the freeze protection required in your area 89 MAINTENANCE AND LUBRICATION Front Brake AWARNING After opening a bottle of brake fluid always discard any unused portion Never store or use a partial bottle Brake fluid is hygroscopic meaning it rapidly absorbs moisture from the air The moisture causes the boiling temperature of the brake fluid to drop which can lead to early brake fade and the possibility of accident or severe injury The front brakes are hydraulic disc brakes They re activated by moving the brake lever toward the handlebar These brakes are self adjusting The following checks are recommended to keep the brake system in good operating condition Check more often if brakes are used heavily under normal operation 1 Always keep brake fluid at an
71. low the engine to sit without oil for extended periods Remove the dipstick 2 and add two quarts 1 9 1 of the recommended oil Reinstall the dipstick NOTE If the sump is not drained add about 1 3 4 quarts initially Place the gear selector in neutral and set the parking brake Start the engine and let it idle for one to two minutes Stop the engine and inspect for leaks Recheck the oil level on the dipstick and add oil as necessary to bring it to the recommended level on the dipstick Dispose of used filter and oil properly 81 MAINTENANCE AND LUBRICATION a 3 4 10 11 12 13 14 15 16 82 il Change 600 700 Place the vehicle on a level surface Run the engine for two to three minutes until warm Stop the engine Clean the area around the drain plug Place a drain pan beneath engine crankcase and remove the drain plug CAUTION Hot oil can cause serious burns Do not allow hot oil to touch skin Allow the oil to drain completely Replace the sealing washer on the drain plug NOTE The sealing surfaces on drain plug and crankcase should be clean and free of burrs nicks or scratches Reinstall the drain plug and torque to 20 ft lbs 27 Nm Place shop towels beneath the oil filter Using an oil filter wrench turn the filter counterclockwise to remove Using a clean dry cloth clean the filter sealing surface on the crankcase Lubricate the o ring on the new filter with a film o
72. n to prevent condensation and may promote corrosion and oxidation Transporting the ATV Follow these procedures when transporting the vehicle 1 Turn off the engine and remove the key to prevent loss during transporting 2 Turn the fuel valve off and be sure the fuel cap oil cap and seat are installed securely 3 Always tie the frame of the ATV to the transporting unit securely with suitable straps or rope 4 Always place the transmission in gear or in PARK if equipped and lock the parking brake 113 ADJUSTMENTS Camber and Caster The camber and caster are non adjustable Rear Spring The rear shock absorber spring is adjusted by rotating the adjuster 1 either clockwise or counterclockwise to increase or decrease spring tension NOTE Accessory springs are available through your Polaris dealer Handlebars AWARNING Improper adjustment of the handlebars or incorrect torquing of the adjuster block tightening bolts can cause limited steering or loosening of the handlebars resulting in loss of control and possible serious personal injury or death Follow the adjustment procedures exactly or see your Polaris dealer for service The handlebars can be adjusted for rider preference 1 Locate handlebar bolts 1 by removing the upper headlight pod 2 Loosen the four bolts 3 Adjust the handlebar to the desired height Be sure the handlebars do not contact the gas tank or any other part of the mach
73. nable to identify solutions using the following charts Engine Doesn t Turn Over Possible Cause Solution Tripped circuit breaker Reset the breaker Low battery voltage Recharge battery to 12 5 VDC Loose solenoid connections Check all connections and tighten Engine Turns Over Fails to Start Possible Cause Solution Mechanical failure Engine Pings or Knocks Possible Cause Solution Poor quality or low octane fuel Replace with recommended fuel Incorrect ignition timing See your Polaris dealer Incorrect spark plug gap or heat range Set gap to specs or replace plugs 118 TROUBLESHOOTING Engine Backfires Possible Cause Solution Weak spark from spark plugs Inspect clean and or replace spark plugs Incorrect spark plug gap or heat range Set gap to specs or replace plugs Mechanical failure Engine Runs Irregularly Stalls or Misfires Possible Weak Spark Cause Solution Other mechanical failure Possible Lean Fuel Mixture Cause Solution Possible Rich Fuel Mixture Cause Solution 119 Kinked or plugged fuel vent line Inspect and replace TROUBLESHOOTING Engine Stops or Loses Power Possible Cause Solution Kinked or plugged fuel vent line Water present in fuel Overuse of choke Fouled or defective spark plugs Worn or defective spark plug wires Incorrect spark plug gap or heat range Loose ignition connections Low battery voltage Clogged air filter Reverse speed limiter malfunction Electroni
74. nge oil more often in cold weather Oil Filter 100 hrs 6 months Replace with oil change 1000 mi Engine breather 100 hrs 6 months Inspect hose F gt gt 71 MAINTENANCE AND LUBRICATION Periodic Maintenance Schedule AWARNING Improperly performing the procedures marked with a m could result in component failure and lead to serious injury or death Have an authorized Polaris dealer perform these services Hours Frequency Miles Carburetor float 50 hrs 6 months Drain bowl periodically and bowl prior to storage Throttle Cable ETC 50 hrs 6 months Inspect adjust lubricate Switch replace if necessary Choke enricher 50 hrs 6 months Inspect adjust lubricate cable replace if necessary Coolant strength 100 hrs 6 months Inspect strength seasonal ly pressure test system annually Drive belt Inspect replace as needed Front suspension 50 hrs 6 months Inspect lubricate tighten fasteners Drive chain s 50 hrs 6 months Inspect daily adjust and lu bricate if needed Spark plug 100 hrs Inspect replace as needed p gt More often under severe use such as dirty or wet conditions Emission Control System Service California Dealer service item 72 MAINTENANCE AND LUBRICATION Periodic Maintenance Schedule Hours Frequency Miles Rearaxle axle Inspect bearings lube Ignition Timing 100 hrs Inspect adjust as needed E Fuel system 100 12 months Check for lea
75. nose Generally the electrodes are not worn General causes of fouling are excessive oil use of non recommended oil improper use of the choke or incorrect carburetion adjustments Spark Plug Removal and Replacement 1 Remove the spark plug cap 2 Using the special wrench provided in the tool pouch rotate the spark plug counterclockwise to remove 3 Reverse the procedure for spark plug installation Torque to 18 ft Ibs 24 Nm 101 MAINTENANCE AND LUBRICATION Vehicle Immersion CAUTION If your vehicle becomes immersed major engine damage can result if the machine is not thoroughly inspected Take the vehicle to your dealer before starting the engine If it s impossible to take your ATV to a dealer before starting it follow the steps outlined below 1 Move the ATV to dry land or at the very least to water below the footrests 2 Check the air box for any water and dry it if water is present Filter replacement is required if water intrusion is evident Turn the fuel valve off Remove the spark plug Loosen the carburetor drain screw 1 AM PW Turn the engine over several times using the electric start Dry the spark plug and reinstall or replace it with a new plug Tighten the carburetor drain screw eo AN Turn the fuel valve on 10 Attempt to start the engine If necessary repeat the drying procedure 11 Take the ATV to your dealer for service as soon as possible whether you succeed
76. nt your vehicle is stolen these numbers are essential to the recovery and identification of your vehicle Remove the spare key and store it in a safe place Your key can be duplicated only by mating a Polaris key blank with one of your existing keys If both keys are lost the ignition switch must be replaced See your Polaris dealer NOTE Record your vehicle s ID numbers and key number 3 in the spaces provided Frame VIN Vehicle Model Number Engine Serial Number Key Number TABLE OF CONTENTS WELCOME fk cca ia hie bd het the e sod Sit bedi Scat 3 VEHICLE IDENTIFICATION NUMBERS 4 TABLE OF CONTENTS 00 cece eee eee 5 SAFETY act operonte oer EE pe tem ried cored be Sees 6 CONTROLS orna wena a E sale deb ateane a h 36 FEATURES enanat armen ana tate aston E N a Ae N 44 OPERATION ae mep au ed ous E GEE E 50 EMISSION CONTROL SYSTEMS 68 MAINTENANCE AND LUBRICATION 69 TROUBLESHOOTING oo cascsvais hea ser 27 ang Bed har beaten Det Aland ang 117 POLARIS PRODUCTS ccs cued ove eatce ee eee pees 121 SPECIFICATIONS 23ers as et ee oe ev be ea eet Seas 122 WARRANTY aises stated ait A one heres 130 INDEX casei vet ceases versa a ate sess 135 SAFETY Safety Decals and Locations Warning decals have been placed on the ATV for your protection Read and follow the instructions on each decal carefully If a decal becomes illegible or comes off contact your Polar
77. om a private citizen outside of the country in which the vehicle was originally purchased all warranty coverage will be denied Notice If your vehicle is registered outside of the country where it was pur chased and you have not followed the procedure set out above your vehicle will no longer be eligible for warranty or service bulletin cover age of any kind Vehicles registered to Government officials or mili tary personnel on assignment outside of the country where the vehicle was purchased will continue to be covered by the basic warranty For questions call Polaris Customer Assistance United States 1 763 417 8650 Canada 1 204 925 7100 134 A ACCESSOTICS 0 eee cece eee 110 ADJUSTMENTS 114 116 Age Restrictions 11 Air Filter Service 00 96 All Wheel Drive 44 Automatic Transmission 43 Auxiliary Brake 91 AWD io aa AEE A A 44 B Battery ea one a a AS 107 109 Battery Conventional 106 Battery Charging Sealed 108 109 Battery Fluid Conventional 108 Battery Installation 107 Battery Removal 107 Battery Storage 108 Belt Eile ker ie aes ain egies Bethe dor uate ov 43 Brake Fluid 39 41 Brake Lever ois wie it ye tee dle es 38 Brake Auxiliary 41 Brake Front 0 000 90 Brake Rear 0 2 2 neins aineet 91 Bre
78. on about all aspects of your vehicle including safe operating procedures Safety Training When you purchased your new ATV your dealer offered a hands on safety training course that covers all aspects of vehicle safety You were also provided with printed materials that explain safe operating procedures You should review this information on a regular basis If you purchased a used Polaris ATV from a party other than a Polaris dealer you can request this free safety training from any authorized Polaris dealer A Polaris ATV is an off road vehicle Familiarize yourself with all laws and regulations concerning the operation of this vehicle in your area We strongly advise you to strictly follow the recommended maintenance program outlined in your owner s manual This preventive maintenance program is designed to ensure that all critical components on your vehicle are thoroughly inspected at specific intervals 11 SAFETY Operator Safety The following two pages identify signal words and symbols that appear in this manual Your safety is involved when these words and symbols are used Become familiar with their meanings before reading the manual The safety alert symbol on your vehicle or in this manual alerts you to the potential for personal injury AWARNING The safety alert warning indicates a potential hazard that may result in serious injury or death 4 CAUTION The safety alert caution indicates a potential haza
79. ons and an average vehicle speed of approximately 10 miles per hour Vehicles subjected to severe use such as operation in wet or dusty areas should be inspected and serviced more frequently Inspect clean lubricate adjust and replace parts as necessary When inspection reveals the need for replacement parts use genuine Polaris parts available from your Polaris dealer NOTE Service and adjustments are critical If you re not familiar with safe service and adjustment procedures have a qualified dealer perform these operations Maintenance Chart Key p Perform these operations more often under severe use such as in dirty or wet conditions to purge water or dirt contamination from grease fittings and other critical components Emission Control System Service California 4 Cycle m Dealer service item 69 MAINTENANCE AND LUBRICATION Periodic Maintenance Schedule Hours of operation are based on a 10 mph average If service is due at 20 hours the equivalent odometer reading would be 200 miles Perform all services at whichever reading is reached first AWARNING Improperly performing the procedures marked with a m could result in component failure and lead to serious injury or death Have an authorized Polaris dealer perform these services Hours Frequency Miles pesen Pence ene reper Amiiay a Premise irepet ris rece a es erica Premio irspest Frame nuts bolts Pre Ride Pre Ride Inspect
80. ot battery gases could accumulate and cause an explosion The tube should be routed away from the frame and body to prevent corrosion Avoid skin contact with electrolyte which can cause severe burns First connect and tighten the red positive cable Second connect and tighten the black negative cable Reinstall the battery cover and attach the hold down strap Oye Vs ie Verify that cables are properly routed NOTE When installing a new battery make sure it s fully charged prior to its initial use Using a new battery that has not been fully charged can damage the battery and result in a shorter life It can also hinder vehicle performance 107 MAINTENANCE AND LUBRICATION Battery Battery Storage When the vehicle is placed in storage for three months or more the battery should be removed stored out of the sun in a cool dry place and tested monthly Before reusing take the battery to your dealer for testing and recharging Power plug leads may need to be bent down so that the battery cover can be installed Replenishing Battery Fluid Conventional Battery A poorly maintained battery will deteriorate rapidly Check the battery fluid level often The fluid level should be kept between the upper and lower level marks 1 To refill use only distilled water Tap water contains minerals that are harmful to a battery AWARNING Improperly connecting or disconnecting battery cables can result in an explosion
81. owner s manual This PVT system is intended for use on Polaris products only Do not install it in any other product Always make sure the PVT housing is securely in place during operation PVT Drying There may be some instances when water is accidently ingested into the PVT system Use the following instructions to dry it out before operating 1 Remove the drain plug and allow the water to drain Replace the drain plug 2 Start the engine and shift the transmission into neutral Apply varying throttle for 10 15 seconds to expel the moisture and air dry the belt and clutches Do not hold the throttle wide open for more than 10 seconds 3 Allow the engine RPM to settle to idle speed then shift the transmission to the lowest available range 4 Test for belt slippage If the belt slips repeat the process 5 Take the vehicle to your dealer for service as soon as possible 105 MAINTENANCE AND LUBRICATION Battery Your ATV may have either a sealed battery which requires little maintenance or a conventional battery Keep the conventional battery terminals and connections free of corrosion If cleaning is necessary remove the corrosion with a stiff wire brush Wash with a solution of one tablespoon baking soda and one cup water Rinse well with tap water and dry off with clean shop towels Coat the terminals with dielectric grease or petroleum jelly Be careful not to allow cleaning solution or tap water into the battery
82. p When the engine idles smoothly push the choke completely in CAUTION Operating the vehicle immediately after starting could cause engine damage Allow the engine to warm up for several minutes before operating the vehicle 53 OPERATION Starting the Engine Starting a Warm Engine Warm engines do not normally require the use of the choke Using the choke can cause the spark plug to become wet fouled 1 Position the vehicle on a level surface with the transmission in neutral or PARK if equipped 2 Lock the parking brake turn the fuel tank valve on sit on the vehicle and turn the engine stop switch to RUN 3 Ifthe engine has cooled to a point where it does not readily start intermittent use of the choke button pulled half way out may be necessary 4 Ifthe engine is over choked when warm depress the throttle lever fully while cranking to aid in starting 5 Release the throttle lever immediately after the engine starts If the engine does not start and all conditions are favorable change the spark plug and try again Cold Weather Operation If the ATV is used year round check the oil level frequently A rising oil level could indicate the accumulation of contaminates such as water or excess fuel in the bottom of the oil tank Water in the bottom of the tank can lead to engine damage and must be drained Water accumulation increases as outside temperature decreases See your Polaris dealer for engine heater k
83. pen throttle berating is vehicle if you ae under ePARKING BRAKE may relax when used for more than 5 minutes ead injury or deale o TASR When parking on grades leave shift in forward NEVER operate this vehicle if you are under age 16 7079085 SAFETY Safety Decals and Locations ATTENTION Operation of this vehicle without the air filter element will severely damage the engine Clean pre filter element often more frequent cleaning required in dusty conditions Do not operate vehicle without pre filter Operation of this vehicle without engine breather filter s can cause engine damage Consult owner s manual or dealer for details 4 WARNING Specific carburetor jetting and adjustments are required depending on temperature and altitude See your Owner s Manual Factory setting 40 to 80 F at 0 3000 feet 5 to 27 C at 0 900 meters 7079902 IMPROPER TIRE PRESSURE OR OVERLOADING can cause loss of control resulting in SEVERE INJURY OR DEATH TIRE PRESSURE IN PSI KPa MAXIMUM WEIGHT CAPACITY Gross Vehicle Weight FRONT 5 34 5 REAR 5 34 5 INCLUDING MACHINE DRIVER AND CARGO IS 1200 LBS 545 kg Reduce speed and allow greater distance for braking when carrying cargo Overloading or carrying tall off center or unsecured loads will increase your risk of losing control Loads should be centered carried as low as possible and firmly secured to the racks With dual racks load distr
84. pod Apply dielectric grease to the light bulb socket before installing the new bulb Make sure the tab on the lamp locates properly in the housing 97 MAINTENANCE AND LUBRICATION Lights High Beam Adjustment The headlight beam can be adjusted to any position desired by turning the adjusting knob on the bottom right side of the headlight pod 1 Position the vehicle on a level surface with the headlight approximately 25 ft 7 6 m from a wall 2 Measure the distance from the floor to the center of the headlight and make a mark on the wall at the same height 3 Start the engine and turn the headlight switch to high beam 4 Observe the headlight aim on the wall The most intense part of the headlight beam should be aimed two inches 5 1 cm below the mark placed on the wall NOTE Include rider weight on the seat when measuring 5 Adjust the beam to the desired position by turning the adjustment knob either clockwise or counterclockwise Snap pins into tabs Position BA i i Slip o ring knob in h over pin locking tabs slot and secure in Route plug Adjustment over handlebar Knob Stop 98 MAINTENANCE AND LUBRICATION Lights Headlight Housing Replacement 1 2 3 10 11 Remove the two screws on the lower front corners of the headlight pod Using a small flat blade screwdriver push in on the lock tab through the two small openings at the front of the headlight pod Lift
85. policy does not apply to Safety Recalls How to Get Service In the Country where your vehicle was purchased Warranty or Service Bulletin repairs must be done by an authorized Polaris dealer If you move or are traveling within the country where your vehicle was purchased Warranty or Service Bulletin repairs may be requested from any authorized Polaris dealer who sells the same line as your vehicle Outside the Country where your vehicle was purchased If you are traveling temporarily outside the country where your vehicle was purchased you should take your vehicle to an authorized Polaris dealer 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 per form 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 be fore you move Vehicles importation rules vary considerably from country to country You may be required to present documentation of your move to Polaris Industries in order to continue your warranty cov erage You may also be required to obtain documentation from Polaris Industries in order to register your vehicle in your new country 133 WARRANTY Exported Vehicles How to Get Service If Purchased From A Private Party If you purchase a Polaris product fr
86. rain and remove the drain plug 2 Catch and discard used oil properly 2 Clean and reinstall the drain plug with a new sealing washer Torque to 14 ft Ibs 19 Nm 3 Remove the fill plug and add 5 ounces 150 ml of the recommended gearcase oil 4 Inspect the oil level which should be maintained level with the bottom of the fill plug hole 5 Reinstall the fill plug Torque to 14 ft Ibs 19 Nm and check for leaks 87 MAINTENANCE AND LUBRICATION Engine Cooling System Coolant Level The recovery bottle 1 is located on the left side of the machine To access the recovery bottle remove the left side panel as outlined on page 93 1 The fluid level must be maintained between the minimum and maximum marks on the bottle when the fluid is cool The engine coolant level is controlled or maintained by the recovery system The recovery system components are the recovery bottle radiator filler neck radiator pressure cap and connecting hose As coolant operating temperature increases the expanding heated excess coolant is forced out of the radiator past the pressure cap and into the recovery bottle As engine coolant temperature decreases the contracting cooled coolant is drawn back up from the tank past the pressure cap and into the radiator NOTE Some coolant level drop on new machines is normal as the system is purging itself of trapped air Observe coolant levels and maintain as recommended b
87. rd that may result in minor personal injury or damage to the vehicle CAUTION A caution indicates a situation that may result in damage to the vehicle NOTE A note will alert you to important information or instructions 12 SAFETY Operator Safety AWARNING Serious injury or death can result if you do not follow these instructions and procedures which are outlined in further detail within your owner s manual Read this manual and all labels carefully and follow the operating procedures described Never operate an ATV without proper instruction Take a training course Beginners should receive training from a certified instructor Contact an authorized Polaris ATV dealer or call Polaris at 1 800 342 3764 to find out about the training courses nearest you Never allow anyone under 16 years of age to operate this ATV Never permit a guest to operate the ATV unless the guest has read this manual and all product labels and has completed a certified safe ty training course Always avoid operating an ATV on paved surfaces including side walks driveways parking lots and streets Never operate an ATV on a public street road or highway including a dirt or gravel road Never operate an ATV without wearing an approved helmet that fits properly Always wear eye protection goggles or face shield gloves boots a long sleeved shirt or jacket and long pants Never consume alcohol or drugs before or while operating an ATV
88. reen 3 AWD diagnostic This gauge indicates whether or not current is flowing through the AWD coil only on models with switchable AWD Screen 4 Gear circuit diagnostic This screen displays the resistance value in ohms being read at the gear switch input of the gauge 48 FEATURES Instrument Cluster Rider Information Center Diagnostic Mode Screen 5 Programmable service interval The purpose of the programmable service interval is to provide the consumer and dealer with a convenient reminder for routine maintenance When your vehicle leaves the factory this feature is set at 50 hours You must enable the programmable service interval before it can be used Once the service interval mode is set with the hours when service is due the hours of actual engine operation are subtracted from the set hours until 0 is reached When the counter reaches 0 the wrench icon will flash quickly for 5 seconds each time the vehicle is started as a reminder that the periodic maintenance is due To set the hours press and hold the mode override button until the wrench icon flashes When it begins to flash release the button The setting will increase by one hour each time the button is pressed Pressing and holding the button will allow the numbers to escalate much faster When the desired time increment is displayed release the button and wait for the wrench to stop flashing When the wrench stops blinking your service hours are set NOTE
89. ring assembly of the ATV should be checked periodically for loose nuts and bolts If loose nuts and bolts are found see your Polaris dealer for service before operating the vehicle MET 92 1 2 MAINTENANCE AND LUBRICATION Side Panel Removal NOTE Side panel removal may be difficult until the locking tabs and receivers have been snapped and unsnapped a few times Remove the seat Grasp the rear of the side panel near the rear cab With a quick and firm motion pull the panel forward and outward to disengage the two rear tabs Place your hand on top of the side panel behind the fuel tank With a quick and firm motion push down on the side panel to disengage the top rear two tabs Then pull up on the side panel to disengage the front upper and lower tabs To reinstall the side panel align the panel tabs with the slots on the front cab Push the panel upward and forward until the tabs lock Bend the rear of the side panel and insert the two tabs into the rear cab Step 2 Step 3 93 MAINTENANCE AND LUBRICATION AWARNING Operating your ATV with worn tires improperly inflated tires non standard tires or improperly installed tires will affect vehicle handling and could cause an accident resulting in serious injury or death Maintain proper tire pressure as described on the decal on your ATV and in the owner s manual
90. rument Cluster Your ATV is equipped with an instrument cluster that senses vehicle speed from the right front wheel The instrument cluster measures distance in miles as well as hours of operation It also includes a reverse speed limiter function that limits the ATV s speed to approximately 7 9 mph Refer to page 36 for additional information P amp SLARIS 1 Rider Information Center Speedometer needle in addition to showing vehicle speed the needle flashes when a warning condition exists 3 Speedometer CAUTION To prevent damage wash the ATV by hand or with a garden hose using mild soap Do not use alcohol to clean the instrument cluster Immediately clean off any gasoline that splashes on the instrument cluster 45 FEATURES Instrument Cluster Rider Information Center The rider information center is located in the instrument cluster All segments will light up for 2 5 seconds at start up NOTE If the instrument cluster fails to illuminate a battery over voltage may have occurred and the instrument cluster may have shut off to protect the electrical system If this occurs take the ATV to your Polaris dealer for proper diagnosis 1 46 Gear Indicator As the shift lever is moved this indicates the gear the transmission is in H High Range 3 4 5 6 L Low Range N Neutral R Reverse P Park if equipped 2 AWD Indicator This indicator illuminates when the electrical portion of the AWD
91. rvice or owner s manual to completely grease and lubricate the entire vehicle with Polaris Premium All Season Grease 112 MAINTENANCE AND LUBRICATION Cleaning and Storage Storage Tips Battery Maintenance Conventional Remove the battery and add distilled water to the proper level Do not use tap water which may contain minerals that reduce battery life Apply dielectric grease to the terminal bolts and terminals Charge the battery at 1 4 amps or less until the specific gravity of each cell is 1 265 or greater Store the battery in a cool dry place Charge can be maintained easily by using Polaris Battery Tender charger PN 2871076 or by charging about once a month to make up for normal self discharge Battery Tender can be left connected during the storage period and will automatically charge the battery if the voltage drops below a pre determined point Check the fluid level monthly Battery Maintenance Sealed Remove the battery and recharge it as outlined on page 108 Store the battery in a cool dry place Engine Anti Freeze Test engine coolant strength and change if necessary Coolant should be replaced every two years Storage Area Covers Set the tire pressure and safely support the ATV with the tires 1 2 off the ground Be sure the storage area is well ventilated and cover the machine with a genuine Polaris ATV cover NOTE Do not use plastic or coated materials They do not allow enough ventilatio
92. s e Personal Task Vehicles PTVs e All Surface Loaders ASLs We believe Polaris sets a standard of excellence for all utility and recreational vehicles manufactured in the world today Many years of experience have gone into the engineering design and development of your Polaris vehicle making it the finest machine we ve ever produced For safe and enjoyable operation of your vehicle be sure to follow the instructions and recommendations in this owner s manual Your manual contains instructions for minor maintenance but information about major repairs is outlined in the Polaris Service Manual and should be performed only by a Factory Certified Master Service Dealer MSD Technician Your Polaris dealer knows your vehicle best and is interested in your total satisfaction Be sure to return to your dealership for all of your service needs during and after the warranty period We also take great pride in our Parts Apparel and Accessories PAA products available through our online store at www purepolaris com Have your accessories and clothing delivered right to your door Polaris Polaris The Way Out and Workmobiles are registered trademarks of Polaris Industries Inc VEHICLE IDENTIFICATION NUMBERS The frame vehicle identification number VIN 1 and engine serial number 2 are important for model identification when registering your vehicle when obtaining insurance and when ordering replacement parts In the eve
93. s reading the trail and avoiding quick sharp turns which can cause skids Correct a skid by turning the handlebars in the direction of the skid and shifting your body weight forward Driving with All Wheel Drive engaged can assist in controlling the vehicle in slippery areas CAUTION Severe damage to drive train may occur if the AWD is engaged while the wheels are spinning Always allow the rear wheels to stop spinning before engaging the AWD AWARNING Failure to exercise care when operating on slippery surfaces can result in loss of tire traction and cause loss of control accident and serious injury or death Never apply the brakes during a skid Do not operate on excessively slippery surfaces Always reduce speed and use additional caution 59 OPERATION Driving Safely Traveling Uphill 25 Maximum Whenever traveling uphill follow these precautions DN Ee Nr 60 Always travel straight uphill Avoid steep hills 25 maximum Keep both feet on the footrests Transfer your weight forward Proceed at a steady rate of speed and throttle opening Remain alert and be prepared to take emergency action This may include quick dismounting of the vehicle AWARNING Braking and handling are greatly affected when operating in hilly terrain Improper procedure could cause loss of control or overturn and result in serious injury or death Avoid climbing steep hills 25 maximum Use extreme caution
94. s stored or parked AWARNING The engine exhaust from this product contains chemicals known to cause cancer birth defects or other reproductive harm Operate this vehicle only outdoors or in well ventilated areas OPERATION Break In Period The break in period for your new Polaris ATV is defined as the first ten hours of operation or the time it takes to use the first two full tanks of gasoline No single action on your part is as important as following the procedures for a proper break in Careful treatment of a new engine will result in more efficient performance and longer life for the engine Perform the following procedures carefully CAUTION Excessive heat build up during the first three hours of operation will damage close fitted engine parts Do not operate at full throttle or high speeds for extended periods during the first three hours of use CAUTION Mixing brands or using a non recommended oil may cause serious engine damage We recommend the use of Polaris Premium 4 synthetic Oil or another OW 40 API certified SH oil Never substitute or mix oil brands 1 Fill the fuel tank with gasoline See page 42 Check the oil reservoir level on the dipstick See page 79 Add oil if necessary to maintain the level between the safe and add marks 3 Drive slowly at first Select an open area that allows room to familiarize yourself with vehicle operation and handling 4 Vary the throttle positions Do not operate at sus
95. ster SPECIFICATIONS SPORTSMAN 400 3 16 1 ee E MacPherson Strut 6 7 2 Single Beam on grill 27 w Jetting and Clutching Charts Sportsman 400 Altitude AMBIENT Below 40 F 40 F and above TEMPERATURE Below 5 C 5 C and above Meters 0 1800 172 5 167 5 Feet 0 6000 1800 3700 6000 12000 Altitude Shift Drive Clutch Driven Helix Weight Spring Clutch and Spring Spring Setting Meters 0 1800 10 BH Blue Green Feet 0 6000 PN 5630711 PN 7041157 PN 7041782 PN 5132344 1800 3700 20 40 Blue Green Black 41 37 6000 12000 PN 5631356 PN 7041157 PN 7041782 PN 5132344 2 2 123 SPECIFICATIONS SPORTSMAN 500 Gross Vehicle Weight 1200 Ibs 544 kg Hitch Towing Rating 1225 lbs 556 kg Unbraked Trailer Towing Capacity 1786 Ibs 810 kg weight not to exceed 180 Ibs 81 6 kg Overall Width 46 in 116 8 cm Overall Height 47 in 119 4 cm Wheelbase 50 5 in 128 3 cm Ground Clearance 11 in 27 9 cm Dry Weight 697 lbs 316 kg Minimum Turning Radius 65 in 165 cm Based on EU Directive 76 432 EC 124 SPECIFICATIONS SPORTSMAN 500 Driving System Type EBS Driving System Type Rear Suspension Progressive rate full independent with anti roll bar 9 5 Shock Adjustment CAM Headlight 1 Single Beam on Handlebar 50 w 2 Single Beam on Grill 27 w Instrument Cluster LCD Jetting and Clutching Charts Sportsman 500 Altitude AMBIENT Below 40 F 40 F and above TEMPERATURE
96. sure washing or submerging Engine Oll Polaris Premium 4 Add to proper level on dip Check level daily Synthetic OW40 stick Brake Fluid DOT 3 Only Maintain level between fill As required change lines See page 39 every two years or 200 hours Transmission Polaris Premium See page 83 400 500 Check every 6 Oil Fig 1 Synthetic Gear or page 85 600 700 months 1000 miles case Lube Change annually or at 100 hours Front Gear Premium Drive See page 84 400 500 Change annually or case Oil Hub Fluid or page 86 600 700 at 100 hours Fig 2 Rear Gear Premium Synthet See page 87 600 700 Change annually or case Oil ic Gearcase Lube at 100 hours Fig 3 or GL5 80 90 weight gear lube Front Prop Grease Grease fittings 3 pumps Every 3 months or Shaft Yoke maximum 50 hours Fig 4 Front Drive Grease Locate grease fitting and Every 3 months or Axle U Joint grease with grease gun 50 hours Fig 5 Ball Joint p gt xGrease Locate fitting on back side of Every 3 months or Fig 6 struts and grease with 50 hours grease gun 76 MAINTENANCE AND LUBRICATION Lubrication Guide 77 MAINTENANCE AND LUBRICATION Premium 4 Synthetic Lubricant Polaris Premium 4 All Season synthetic engine oil has been specially formulated for use in Polaris 4 cycle engines It s a fully synthetic high performance multi viscosity oil designed to provide
97. t be screwed completely in to keep the angle and depth of the stick consistent 5 Remove the dipstick and AFE ADR 8 0 check the oil level Maintain the oil level in the normal or safe range 3 depending on 3 the style of dipstick in your model Do not overfill 6 After reinstalling the rae pice ene ae dipstick be sure to seat the lever lock if 3 equipped 79 MAINTENANCE AND LUBRICATION Oil and Filter Change The recommended oil change interval is 100 hours 1000 miles or every six months whichever comes first Suggested break in oil change is at 20 hours 200 miles or one month whichever comes first Severe use operation requires more frequent service Severe use includes continuous duty in dusty or wet conditions and cold weather riding NOTE Severe use cold weather riding is all riding below 10 F and riding between 10 F and 30 F when most trips are slow speed and less than five miles Be sure to change the oil filter whenever changing the oil a Change 400 500 Position the vehicle on a level surface Clean the area around the drain plug at the bottom of the oil tank and the bottom of the engine 2 Run the engine for two to three minutes then turn it off 3 Place a drain pan beneath the oil tank and remove the drain plug 1 Allow the oil to drain completely 4 Install a new sealing washer 2 on the oil drain plug NOTE The sealing surfaces on the drain plug and the oil tank should be clean
98. t you use your original selling dealer however you may use any Polaris Servicing Dealer to perform warranty service Please work with your dealer to resolve any warranty issues 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 rights which vary from state to state If any of the above terms are void because of state or federal law all other warranty terms will remain in effect Engine Oil 1 Mixing oil brands or using non recommended oil may cause engine damage We recommend the use of Polaris engine oil for your ATV 2 Damage resulting from the use of non recommended lubricants may not be covered by warranty 132 WARRANTY Exported Vehicles EXCEPT WHERE SPECIFICALLY REQUIRED BY LAW THERE IS NO WARRANTY OR SERVICE BULLETIN COVERAGE ON THIS VEHICLE IF IT IS SOLD OUTSIDE THE COUNTRY OF THE SELLING DEALER S AUTHORIZED LOCATION This policy does not apply to vehicles that have received authorization for export from Polaris Industries Dealers may not give authorization for export You should consult an authorized dealer to determine this vehicle s warranty or service bulletin coverage if you have any ques tions This policy does not apply to vehicles registered to government offi cials or military personnel on assignment outside the country of the selling dealer s authorized location This
99. tained idle 5 Perform regular checks on fluid levels controls and areas outlined on the daily pre ride inspection checklist See page 52 6 Pull only light loads 7 During the break in period change both the oil and the filter at 20 hours or 200 miles 51 OPERATION Pre Ride Inspection AWARNING If a proper inspection is not done before each use severe injury or death could result Always inspect the vehicle before each use to ensure it s in proper operating condition Use the following checklist to verify that your vehicle is in proper working condition before each use Item Inspection Procedure 1 Tires Check condition and pressures 2 Fuel tank and engine oil level Fill both to their proper levels 3 All brakes Check operation adjustment and fluid levels includes auxiliary brake 4 Throttle Check for free operation and closing 5 Headlight Taillight Brakelight Check operation of all indicator lights and switches 6 Engine stop switch Check for proper function 7 Wheels Check for tightness of wheel nuts and axle nuts check that axle nuts are secured by cotter pins 8 Air cleaner element Check for dirt clean or replace 9 Steering Check for free operation noting any unusual looseness in any area 10 Loose parts Visually inspect the vehicle for any damaged components or loose nuts bolts or fasteners 11 Riding gear Wear a helmet goggles and protective clothing 1
100. the pod slightly while depressing the tabs Remove the screw in the back of the headlight pod Lift the pod cover Disconnect the speedometer harnesses from the 1 speedometer Unplug the indicator light harness and remove the pod cover Unplug the headlamp from the wiring harness Remove the o ring 1 from the headlight pivot pins Pull the headlight housing up to release from the locking tabs Lift the adjusting knob up to remove from the locking tabs 13 cm Carefully pull the assembly up and out of pod Reverse the steps to install the new housing and reassemble the pod NOTE The distance from the headlamp parting line to the end of the adjustment knob stop is 5 1 8 13 cm See illustration 12 Adjust the headlight aim by turning the adjusting knob 99 MAINTENANCE AND LUBRICATION Lights Lower Headlamp Removal Installation 1 Turn the back of the headlight harness 1 in a clockwise direction 2 Pull the harness assembly out from the headlight f assembly Pa 3 Remove the headlamp and replace with a 1 new headlamp 4 Install the new headlamp and harness assembly into the headlight assembly Turn the headlight harness counterclockwise to secure the headlamp into place Taillight Brakelight Lamp Replacement If the taillight brakelight does not work the lamp may need to be replaced 1 Remove the taillight lens cover mounting screws 1 Remove the lens cover 2 and gasket and
101. the ultimate in lubrication performance and protection NOTE See page 121 for the part numbers of Polaris products Premium 4 possesses unsurpassed film strength over the widest possible temperature range It resists viscosity and frictional breakdown in ambient temperatures from 40 F to 120 F 40 to 49 C Its exceptional frictional properties result in more efficient operation more power output and lower fuel consumption Although Polaris Premium 4 is the only oil recommended for use in this engine use of any API certified SH oil is allowable as long as it s OW 40 Oil may need to be changed more frequently if Polaris Premium 4 is not used Follow the manufacturer s recommendations for ambient temperature operation CAUTION Mixing brands or using a non recommended oil may cause serious engine damage We recommend the use of Polaris Premium 4 synthetic Oil or another OW 40 API certified SH oil Never substitute or mix oil brands 78 MAINTENANCE AND LUBRICATION Oil Check The oil dipstick and fill tube 1 are located on the left side of the vehicle 1 Position the ATV on a level surface 2 Start the engine and let it idle for 20 30 seconds 3 Stop the engine Remove the dipstick and wipe it dry with a clean cloth NOTE If your dipstick is equipped with a lever lock 2 lift the lock to remove the dipstick 4 Reinstall the dipstick completely but do not lock it if equipped The dipstick mus
102. the upper body first and the lower parts last Rinse with water frequently and dry with a chamois to prevent water spots NOTE If warning and safety labels are damaged contact your a Polaris dealer for free replacement Polaris does not recommend the use of a high pressure type car wash system for washing the ATV If a high pressure system is used exercise extreme care to avoid water damage to the wheel bearings transmission seals body panels brakes and warning labels NOTE Grease all zerk fittings immediately after washing and allow the vehicle to run for a while to evaporate any water that may have entered the engine or exhaust system Waxing the ATV Your ATV can be waxed with any non abrasive automotive paste wax Avoid the use of harsh cleaners since they can scratch the body finish CAUTION Certain products including insect repellants and chemicals will damage plastic surfaces Use caution when using these products near plastic surfaces 110 MAINTENANCE AND LUBRICATION Cleaning and Storage Storage Tips CAUTION Starting the engine during the storage period will disturb the protective film created by fogging and damage could occur Never start the engine during the storage period Clean the Exterior Make necessary repairs and then clean the ATV thoroughly with mild soap and warm water to remove all dirt and grime Don t use harsh detergents or high pressure washers Some detergents deteriorate rubber parts Us
103. times carefully Stop charging if the battery becomes very warm to the touch Allow it to cool before resuming charging NOTE Always verify battery condition before and 1 2 hours after the end of charging State of Voltage Charge Time Charge Using constant current charger standard amps specified on top of battery 100 12 8 13 0 volts None check at None required 3 mos from date of manufacture 75 100 12 5 12 8 volts May need slight 3 6 hours charge if no charge given check in 3 months 50 75 12 0 12 5 volts Needs Charge 5 11 hours 2 7 i 5 50 11 5 12 0 volts Needs Charge At least 13 hours verify state of charge 0 25 11 5 volts or less Needs Charge At least 20 hours 109 MAINTENANCE AND LUBRICATION Accessories Auxiliary power outlets provide 12V power for operating accessories such as hand held spot lights Accessory outlets are available for all models Polaris also has a wide range of additional accessories available for your ATV See your Polaris dealer Cleaning and Storage See page 121 for the part numbers of Polaris products Cleaning the ATV Keeping your ATV clean will not only improve its appearance but it can also extend the life of various components With a few precautions your ATV can be cleaned much like an automobile Washing the ATV The best and safest way to clean your ATV is with a garden hose and a pail of mild soap and water Use a professional type washing mitten cleaning
104. tral or PARK if equipped and repeat steps 3 and 4 until no more particles are expelled when the engine is revved Stop the engine and allow the arrestor to cool Reinstall the arrestor plug and remove the outlet cover or plug 103 MAINTENANCE AND LUBRICATION PVT System The basic operation of the Polaris PVT system is dependent on engine speed and vehicle torque requirements As engine speed increases the force exerted on the movable drive sheave by the flyweights also increases This in turn increases the amount of pinch applied to the drive belt Similarly if the engine speed decreases the amount of centrifugal force decreases reducing the amount of belt pinch On Polaris ATVs the approximate gear ratio difference between high and low range is 1 2 25 This difference in gearing affects the operation of the PVT especially at speeds less than 7 MPH 11 KPH due to the system s dependence on engine speed For example when operating at a ground speed of 3 MPH 5 KPH in low range the engine speed would be around 3000 RPM This is well above the engagement speed of 1200 1400 RPM However in high range at 3 MPH 5 KPH the engine would be running at only 1500 RPM Whenever operating this close to the engagement speed the engine may be running at a speed too low to provide the pinch needed to prevent belt slip Belt slip is responsible for creating the excessive heat that destroys belts and causes outer clutch covers to fail
105. ver 1 The throttle lever is spring loaded Engine speed returns to idle when the lever is released This ATV is equipped with Polaris Electronic Throttle Control ETC which is designed to reduce the risk of a frozen or stuck throttle If the throttle cable should stick in an open position when the operator releases the throttle lever the engine will stop and power to the rear wheels will cease AWARNING The Electronic Throttle Control ETC stops the engine in the event of a throttle system malfunction and is provided for your safety Do not attempt to modify the ETC system or replace it with any after market throttle mechanisms 37 CONTROLS Light Switches The light switch is located on the left handlebar It s used to turn the lights on and off and to switch the lights from HI to LO NOTE The lights won t work unless the key is in the ON position and the shut off switch is in the RUN position AWARNING Operating the ATV on streets or roads especially in darkness could result in an accident and serious injury or death Your ATV is not equipped with highway approved lights It s designed for and must be used for off road use only Use caution and drive at reduced speeds in conditions of reduced visibility such as fog rain and darkness Brake Lever The front and rear brakes are applied 1 by squeezing the brake lever 1 toward the handlebar The front and of E rear brakes are hydraulically f activated
106. when operating on hills and follow proper operating procedures outlined in the owner s manual OPERATION Driving Safely Sidehilling AWARNING Improperly crossing hills or turning on hills can result in loss of control or vehicle overturn resulting in severe injury or death Avoid crossing the side of a hill when possible Follow proper procedures as outlined in the owner s manual Sidehilling can be a dangerous type of driving and should be avoided if at all possible If you do enter into a situation where sidehilling is necessary follow these precautions 1 Slow down 2 Lean into the hill transferring your upper body weight toward the hill while keeping your feet on the footrests 3 Steer slightly into the hill to maintain vehicle directions NOTE If the vehicle begins to tip quickly turn the front wheel downhill if possible or dismount on the uphill side immediately 61 OPERATION Driving Safely Traveling Downhill Whenever descending a hill follow these precautions 1 Proceed directly downhill 2 Transfer your weight to the rear of the vehicle 3 Slow down 4 Apply the brakes slightly to aid in slowing Familiarize yourself with operation of the auxiliary brake in the event loss of normal service brakes occurs AWARNING Excessive speed can cause loss of control and lead to serious injury or death Always operate slowly when traveling downhill 62 OPERATION Driving Safely Turning
107. y adding coolant to the recovery bottle Polaris recommends the use of Polaris Premium 60 40 anti freeze coolant or a 50 50 mixture of high quality aluminum compatible anti freeze coolant and distilled water See page 121 for the part numbers of Polaris products NOTE Polaris Premium 60 40 is already premixed and ready to use Do not dilute with water NOTE Always follow the manufacturer s mixing recommendations for the freeze protection required in your area 88 MAINTENANCE AND LUBRICATION Engine Cooling System AWARNING Escaping steam can cause severe burns Never remove the pressure cap while the engine is warm or hot Always allow the engine to cool before removing the pressure cap Radiator Coolant Level ie NOTE This procedure is required 2 ee only if the cooling system has been Soo drained for maintenance and or repair o 8 run dry the level in the radiator NAN i should be inspected and coolant 5 added if necessary 0a Q 1 Using the tool provided remove the four screws securing the front rack 1 Remove the front cover 2 by placing your fingers under the front of the cover and pulling upward However if the recovery bottle has 2 Remove the pressure cap 3 Using a funnel slowly add coolant as necessary through the radiator filler neck 4 Replace the pressure cap and secure the front cover and rack NOTE Use of a non standard pressure cap will not al

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