WARNING 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.
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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 2 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.
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 event 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.
TABLE OF CONTENTS WELCOME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 VEHICLE IDENTIFICATION NUMBERS . . . . . . . . . . . . . . . 4 TABLE OF CONTENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 FEATURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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 Polaris dealer to purchase a replacement. Replacement safety decals are provided by Polaris at no charge. The part number is printed on the decal. WARNING IF OWNER’S MANUAL IS MISSING, CONTACT A POLARIS DEALER FOR A REPLACEMENT.
Safety Decals and Locations SAFETY ATTENTION S Operation of this vehicle without the air filter element will severely damage the engine. S Clean pre-filter element often, more frequent cleaning required in dusty conditions. Do not operate vehicle without pre-filter. S Operation of this vehicle without engine breather filter(s) can cause engine damage. Consult owner’s manual or dealer for details. S Specific carburetor jetting and adjustments are required depending on temperature and altitude.
SAFETY Safety Decals and Locations 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 WARNING S 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. S Max Rack Loads: Front 90 lbs.
SAFETY Safety Decals and Locations WARNING Pushing reverse override button may cause sudden increases in power and traction if too much throttle is applied. Loss of control or forward flipover may result, especially in AWD. See Owner’s Manual. ALL WHEEL DRIVE SWITCH Do not push switch to engage AWD if the rear wheels are spinning. This may cause severe drive shaft and clutch damage. See your Owner’s Manual. MANUFACTURED BY: POLARIS IND INC.
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.
SAFETY Operator Safety WARNING 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.
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. WARNING The safety alert warning indicates a potential hazard that may result in serious injury or death.
SAFETY Operator Safety WARNING 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. S Read this manual and all labels carefully, and follow the operating procedures described. S Never operate an ATV without proper instruction. Take a training course. Beginners should receive training from a certified instructor.
SAFETY Operator Safety S Always have the ATV inspected by an authorized Polaris dealer if it’s been involved in an accident. S Never operate on hills too steep for the ATV or for your abilities. Practice on smaller hills before attempting larger hills. S Always follow proper procedures for climbing hills. Check the terrain carefully before ascending a hill. Never climb hills with excessively slippery or loose surfaces. Shift your weight forward. Never open the throttle suddenly or make sudden gear changes.
Operator Safety SAFETY S 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. S Always check for obstacles or people behind the ATV before operating in reverse. When it’s safe to proceed in reverse, move slowly and avoid turning at sharp angles. S Always use the size and type of tires specified for your ATV, and always maintain proper tire pressure.
SAFETY Operator Safety 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.
SAFETY Operator Safety 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.
SAFETY Operator Safety WARNING 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.
SAFETY Operator Safety WARNING 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.
SAFETY Operator Safety 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.
SAFETY Operator Safety 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 Never consume alcohol or drugs before or while operating an ATV.
SAFETY Operator Safety 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 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.
SAFETY Operator Safety 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.
SAFETY Operator Safety 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.
SAFETY Operator Safety WARNING POTENTIAL HAZARD Turning improperly. WHAT CAN HAPPEN Improper turns could cause loss of control and 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. WARNING POTENTIAL HAZARD Operating on excessively steep hills. WHAT CAN HAPPEN The vehicle may overturn.
SAFETY Operator Safety 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.
SAFETY Operator Safety WARNING POTENTIAL HAZARD Traveling downhill improperly. WHAT CAN HAPPEN Improperly descending a hill could cause 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.
SAFETY Operator Safety 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.
SAFETY Operator Safety 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 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.
SAFETY Operator Safety 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. WARNING POTENTIAL HAZARD Skidding or sliding.
SAFETY Operator Safety WARNING 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.
SAFETY Operator Safety 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. Always maintain proper tire pressure as described in the owner’s manual and on safety decals.
SAFETY Operator Safety 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.
SAFETY Operator Safety WARNING 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. WARNING Safe operation of this rider-active vehicle requires good judgement and physical skills.
CONTROLS Engine Electrical Switches WARNING 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. 2 1 3 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.
CONTROLS WARNING 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.
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. WARNING 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.
CONTROLS Master Cylinder 1 The brake fluid in the master 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.
CONTROLS Parking Brake WARNING 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 1. Place the transmission in first gear (or in PARK if equipped). 2. Squeeze and release the brake lever (1) two or three times, then squeeze and hold. 3. Push the park brake lock (2) forward to engage the brake. Release the brake lever. 4.
CONTROLS Auxiliary Brake WARNING 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 ATV has an auxiliary brake (1) for added safety.
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 panel. It has three positions: OFF: For vehicle storage and when transporting. ON: For normal operation. RES: For reserve supply if main supply is exhausted. NOTE: There’s about a 7 to 10 mile (11.2 to 16 km) range on reserve gas.
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.
FEATURES All Wheel Drive (AWD) System 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 1 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.
Instrument Cluster FEATURES 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. 3 2 1 1. Rider Information Center 2. Speedometer needle - in addition to showing vehicle speed, the needle flashes when a warning condition exists.
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.
Instrument Cluster FEATURES 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.
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.
Instrument Cluster FEATURES 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.
OPERATION Fuel Safety WARNING Gasoline is highly flammable and explosive under certain conditions. S Always exercise extreme caution whenever handling gasoline. S Always refuel with the engine stopped, and outdoors or in a S S S S S well ventilated area. Do not smoke or allow open flames or sparks in or near the area where refueling is performed or where gasoline is stored. Do not overfill the tank. Do not fill the tank neck.
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.
OPERATION Pre-Ride Inspection WARNING 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.
Starting the Engine OPERATION Starting a Cold Engine WARNING 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). 1 NOTE: The variable choke is fully on when the knob is pulled completely out.
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.
Hauling Cargo 2/3 OPERATION 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.
OPERATION Hauling Cargo WARNING 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: S REDUCE SPEED AND ALLOW GREATER DISTANCES FOR BRAKING WHEN HAULING CARGO. S 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.
Driving Safely OPERATION 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. 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.
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.
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. Slow down when entering slippery areas. 2. Maintain a high level of alertness, reading the trail and avoiding quick, sharp turns, which can cause skids. 3. Correct a skid by turning the handlebars in the direction of the skid and shifting your body weight forward. 4.
OPERATION Driving Safely Traveling Uphill 25_ Maximum Whenever traveling uphill, follow these precautions: 1. Always travel straight uphill. 2. Avoid steep hills (25_ maximum). 3. Keep both feet on the footrests. 4. Transfer your weight forward. 5. Proceed at a steady rate of speed and throttle opening. 6. Remain alert and be prepared to take emergency action. This may include quick dismounting of the vehicle. WARNING Braking and handling are greatly affected when operating in hilly terrain.
OPERATION Driving Safely Sidehilling WARNING 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.
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. WARNING Excessive speed can cause loss of control and lead to serious injury or death. Always operate slowly when traveling downhill.
OPERATION Driving Safely Turning Around on a Hill WARNING 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.
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 procedures when operating through water: 1. Determine water depths and current before crossing. 2. Choose a crossing 1 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.
OPERATION 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. WARNING 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.
OPERATION Driving Safely Driving in Reverse Follow these precautions when operating in reverse: 1. Always avoid backing downhill. 2. Back slowly. 3. When in reverse, apply the brakes lightly for stopping. 4. Avoid turning at sharp angles in reverse. 5. Never open the throttle suddenly while backing. WARNING 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.
Driving Safely OPERATION Parking on an Incline Avoid parking on an incline if possible. If it’s unavoidable, follow these precautions: 1. Turn the engine off. 2. Place the transmission in low range (or park if equipped). 3. Set the parking brake. 4. Always block the rear wheels on the downhill side as shown in the illustration. 5. Shut off the fuel supply.
EMISSION CONTROL SYSTEMS Noise Emission Control System TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED! U.S.
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 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. WARNING Improperly performing the procedures marked with a J could result in component failure and lead to serious injury or death. Have an authorized Polaris dealer perform these services.
MAINTENANCE AND LUBRICATION Periodic Maintenance Schedule Item " Air box sediment Hours/ Miles Frequency Remarks Pre-Ride Pre-Ride Drain deposits whenever visible Headlamp Pre-Ride Pre-Ride Check operation daily; apply Polaris dielectric grease to connector when replaced Tail lamp/brake lamp Pre-Ride Pre-Ride Check operation daily; apply Polaris dielectric grease to socket when replaced " Air filter, Weekly Weekly Inspect; replace as needed " Transmission oil 20 hrs Monthly Inspect monthl
MAINTENANCE AND LUBRICATION Periodic Maintenance Schedule WARNING Improperly performing the procedures marked with a J could result in component failure and lead to serious injury or death. Have an authorized Polaris dealer perform these services. Item Hours/ Miles Frequency Remarks Carburetor float bowl 50 hrs. 6 months Drain bowl periodically and prior to storage J Throttle Cable/ETC 50 hrs. 6 months Inspect; adjust; lubricate; replace if necessary L Choke (enricher) 50 hrs.
MAINTENANCE AND LUBRICATION Periodic Maintenance Schedule Item Hours/ Miles Frequency Remarks " Rear axle 50 hrs. 6 months Inspect bearings; lube J Ignition Timing 100 hrs. 12 months Inspect; adjust as needed 100 hours 12 months L Check for leaks at tank cap, lines, fuel valve, filter, pump and carburetor; replace lines every two years J Fuel filter 100 hrs. 12 months Replace annually Radiator 100 hrs. 12 months Inspect; clean external surface Cooling system hoses 100 hrs.
MAINTENANCE AND LUBRICATION Periodic Maintenance Record Use the following chart to record periodic maintenance. Maintenance Interval Performed 10 hrs. 20 hrs. 50 hrs. 100 hrs.
- 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 " More often under severe use, such as wet or dusty conditions F No.
MAINTENANCE AND LUBRICATION Lubrication Guide (Fig. 1) (Fig. 1) (Fig. 2) (Fig. 2) (Fig. 3) (Fig. 4) (Fig. 6) (Fig.
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 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.
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. 1 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. 2 4. Reinstall the dipstick completely, but do not lock it (if equipped).
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.
MAINTENANCE AND LUBRICATION Oil Change (400/500) 7. Place shop towels beneath the oil filter. Using an oil filter wrench, turn the filter (1) counterclockwise and remove. 8. 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. 9. Install the new filter and tighten by hand 1/2 to 3/4 turn after gasket contacts the engine. 10.
MAINTENANCE AND LUBRICATION Oil Change (600/700) 1. Place the vehicle on a level surface. 2. Run the engine for two to three minutes until warm. Stop the engine. 3. Clean the area around the drain plug. 4. 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. 5. Allow the oil to drain completely. 6. Replace the sealing washer on the drain plug.
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.
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 GL5 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.
MAINTENANCE 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.
MAINTENANCE AND LUBRICATION Front Gearcase Oil (600/700) 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. 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.
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 GL5 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).
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.
MAINTENANCE AND LUBRICATION Engine Cooling System WARNING 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 2 NOTE: This procedure is required only if the cooling system has been drained for maintenance and/or repair. However, if the recovery bottle has 1 run dry, the level in the radiator should be inspected and coolant added if necessary. 1.
MAINTENANCE AND LUBRICATION Front Brake WARNING 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.
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. 3/64″ (.
MAINTENANCE AND LUBRICATION Toe Alignment WARNING 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 straight-ahead position.
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. 1. Remove the seat. Step 2 2. 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. 3. Place your hand on top of the side panel behind the fuel tank.
MAINTENANCE AND LUBRICATION WARNING 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. 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″ (.
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.
MAINTENANCE AND LUBRICATION Filter Systems Air Filter Service 1 1. Remove the seat, release the air box cover clips, and 2 remove the air box cover. 2. Loosen the clamp and remove the filter. 3. Remove the fabric type pre-filter (1) from the main filter (2). Wash the pre-filter in soapy water, then rinse and 3 let dry. 4. Reinstall the pre-filter over the main filter. (Replace the main filter if needed.) 5. Reinstall the filter into the air box and tighten the clamp.
Lights MAINTENANCE AND LUBRICATION 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. WARNING 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.
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.
Lights MAINTENANCE AND LUBRICATION Headlight Housing 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. Disconnect the 1 speedometer harnesses from the speedometer.
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 assembly. 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.
MAINTENANCE AND LUBRICATION Spark Plugs S S S S Use BKR5E 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.
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.
MAINTENANCE AND LUBRICATION Spark Arrestor WARNING 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.
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.
MAINTENANCE AND LUBRICATION PVT System WARNING 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.
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.
Battery MAINTENANCE AND LUBRICATION Battery Removal 1. Disconnect the hold-down strap holding the battery in position, and remove battery cover. 2. On conventional batteries, remove the battery vent tube. 3. Disconnect the black (negative) battery cable first. 4. Disconnect the red (positive) battery cable next. 5. Lift the battery out of the ATV. Be careful not to tip a conventional battery sideways, which could spill electrolyte.
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.
Battery MAINTENANCE AND LUBRICATION 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. If the 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.
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.
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. Use dish soap type cleaners only.
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 leak. 2. Reinstall the spark plug.
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.
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.
Carburetor/Idle RPM ADJUSTMENTS 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.
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.
TROUBLESHOOTING Drive Belt and Cover Problems Possible Cause Solution Driving the ATV onto a pickup or tall trailer in high range. Shift transmission to low range during loading of the ATV to prevent belt burning. Starting out going up a steep incline. When starting out on an incline, use low range or dismount 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.
TROUBLESHOOTING Contact your Polaris dealer for service if you’re unable 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.
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 Old or non-recommended fuel Replace with new fuel Incorrectly installed spark plug wires See your Polaris dealer Incorrect ignition timing See your Polaris dealer Mechanical failure See your Polaris dealer Engine Runs Irregularly, Stalls or Misfires Possible Weak Spark Cause Solution Fouled or d
TROUBLESHOOTING Engine Stops or Loses Power Possible Cause Solution Out of fuel Turn fuel valve to reserve, refuel Kinked or plugged fuel vent line Inspect and replace Water present in fuel Replace with new fuel Overuse of choke Inspect, clean and/or replace spark plugs Fouled or defective spark plugs Inspect, clean and/or replace spark plugs Worn or defective spark plug wires See your Polaris dealer Incorrect spark plug gap or heat range Set gap to specs or replace plugs Loose ignition conn
POLARIS PRODUCTS Part No. Description Engine Lubricant 2870791 Fogging Oil (12 oz. Aerosol) 2871281 Engine Oil (qt.) Premium 4 Synthetic 0W-40 (4-Cycle) 2871844 Engine Oil (gal.) Premium 4 Synthetic 0W-40 (4-Cycle) Gearcase / Transmission Lubricants 2871477 Premium Synthetic Gearcase Lubricant (1 gal.) 2871478 Premium Synthetic Gearcase Lubricant (12 oz. bottle) 2871653 Gear Drive Fluid (12 oz.) 2872276 Gear Drive Fluid (2.5 gal.
SPECIFICATIONS SPORTSMAN 400 Gross Vehicle Weight 1200 lbs./544 kg Towing Capacity 1225 lbs./556 kg Hitch Tongue Capacity 120 lbs./54 kg (Rear rack weight and tongue weight not to exceed 180 lbs./81.6 kg) Front Rack Capacity 90 lbs./40.8 kg Rear Rack Capacity 180 lbs./81.6 kg Overall Length 81 in./205.7 cm Overall Width 46 in./119.3 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.
SPECIFICATIONS SPORTSMAN 400 Shift Type Side Lever (High, Low, Neutral, Reverse) Gear Reduction - Low 8.27/1 Gear Reduction - Reverse 5.17/1 Gear Reduction - Forward 3.34/1 Drive Ratio - Front 2:1 Drive Ratio - Final 3.
SPECIFICATIONS SPORTSMAN 500 Gross Vehicle Weight 1200 lbs./544 kg Hitch Towing Rating 1225 lbs./556 kg Unbraked Trailer Towing Capacity* Hitch Tongue Capacity 1786 lbs./810 kg 120 lbs./54 kg (Rear rack weight and tongue weight not to exceed 180 lbs./81.6 kg) Front Rack Capacity 90 lbs./40.8 kg Rear Rack Capacity 180 lbs./81.6 kg Overall Length 81 in./205.7 cm 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.
SPECIFICATIONS SPORTSMAN 500 Driving System Type EBS Shift Type Side Lever (High, Low, Neutral, Reverse) Gear Reduction - Low 8.27/1 Gear Reduction - Reverse 5.17/1 Gear Reduction - Forward 3.34/1 Drive Ratio - Front 2:1 Drive Ratio - Final 3.
SPECIFICATIONS SPORTSMAN 600 Gross Vehicle Weight 1240 lbs./563 kg Fuel Capacity 4.75 gal./18 l Towing Capacity 1500 lbs./681 kg Hitch Tongue Capacity 150 lbs./68.1 kg (Rear rack capacity and tongue weight not to exceed 200 lbs./90.7 kg) Front Rack Capacity 100 lbs./45.4 kg Rear Rack Capacity 200 lbs./90.8 kg Overall Length 85 in./215.9 cm Overall Width 46 in./116.8 cm Overall Height 47 in./119.4 cm Wheelbase 50.75 in./128.9 cm Ground Clearance 11 in./27.9 cm Dry Weight 740 lbs.
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 25 x 8 - 12 Tire Size - Rear 25 x 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.
SPECIFICATIONS SPORTSMAN 700 Gross Vehicle Weight Fuel Capacity Towing Rating Unbraked Trailer Towing Capacity* Front Rack Capacity Rear Rack Capacity Hitch Tongue Capacity Overall Length Overall Width Overall Height Wheelbase Ground Clearance Dry Weight Minimum Turning Radius Engine Oil Capacity Coolant Capacity Engine Displacement Bore x Stroke Pilot Jet Main Jet Needle Jet Jet Needle Pilot Screw Alternator Output Compression Ratio Starting System Carburetor Ignition System Ignition Timing Spark Plug / Ga
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 25 x 8 - 12 Tire Size - Rear 25 x 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.
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.
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.
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.
Exported Vehicles WARRANTY 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 questions.
WARRANTY Exported Vehicles How to Get Service If Purchased From A Private Party: If you purchase a Polaris product from 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 purchased, and you have not followed the procedure set out above, your vehicle will no longer be eligible for warranty or service bulletin coverage of any kind.
INDEX A Accessories . . . . . . . . . . . . . . . . . . . . 110 ADJUSTMENTS . . . . . . . . . . . 114-116 Age Restrictions . . . . . . . . . . . . . . . . . 11 Air Filter Service . . . . . . . . . . . . . . . . 96 All Wheel Drive . . . . . . . . . . . . . . . . . 44 Automatic Transmission . . . . . . . . . . . 43 Auxiliary Brake . . . . . . . . . . . . . . . . . 91 AWD . . . . . . . . . . . . . . . . . . . . . . . . . . 44 B Battery . . . . . . . . . . . . . . . . . . . 107-109 Battery (Conventional) . . .
INDEX M S Main Switch . . . . . . . . . . . . . . . . . . . . 36 MAINTENANCE AND LUBRICATION . . . . 69-113 Maintenance Record . . . . . . . . . . . . . . 74 Making Turns . . . . . . . . . . . . . . . . . . . 58 Master Cylinder . . . . . . . . . . . . . . . . . 39 Sidehilling . . . . . . . . . . . . . . . . . . . . . 61 Spark Arrestor . . . . . . . . . . . . . . . . . 103 Spark Plug Replacement . . . . . . . . . 101 Spark Plugs . . . . . . . . . . . . . . . . . . . . 101 SPECIFICATIONS . . . . . . . . .
WARNING Improper vehicle use can result in SEVERE INJURY or DEATH. ALWAYS USE AN APPROVED HELMET AND PROTECTIVE GEAR NEVER USE ON PUBLIC ROADS NEVER CARRY PASSENGERS NEVER USE WITH DRUGS OR ALCOHOL NEVER: Operate without proper training or instruction. Operate on public roads. A collision can occur with another vehicle. Operate at speeds too fast for your skills or the conditions. Use ALCOHOL or DRUGS before or while operating this vehicle. Carry Passengers.
