Polaris 700 - Manuals

4 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 e...

5 TABLE OF CONTENTS WELCOME 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . VEHICLE IDENTIFICATION NUMBERS 4 . . . . . . . . . . . . . . . TABLE OF CONTENTS 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SAFETY 6 . . . . . . . . . . . . . . . . . . . . ...

6 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 P...

8 SAFETY Safety Decals and Locations 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 d...

10 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 injur...

11 SAFETY Operator Safety 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. Rea...

12 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, a...

13 SAFETY Operator Safety 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. Contact an authorized Polaris ATV dealer or...

15 SAFETY Operator 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 operat- ing in reverse. When it’s safe to ...

16 SAFETY Operator Safety POTENTIAL HAZARDOperating this ATV without proper instruction.WHAT CAN HAPPENThe 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 HAZARDBeginning...

17 SAFETY Operator Safety POTENTIAL HAZARDCarrying a passenger on an ATV.WHAT CAN HAPPENCarrying 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 HAZARDNever carry a passenger...

18 SAFETY Operator Safety POTENTIAL HAZARDOperating an ATV on paved surfaces, including sidewalks, paths, parking lots, and driveways.WHAT CAN HAPPENATV 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, ...

19 SAFETY Operator Safety POTENTIAL HAZARDOperating this ATV on public streets, roads or highways.WHAT CAN HAPPENThe ATV could collide with another vehicle.HOW TO AVOID THE HAZARDNever operate the ATV on any public street, road or highway, including dirt and gravel roads. In many states it’s illegal...

20 SAFETY Operator Safety POTENTIAL HAZARDOperating this ATV without wearing an approved helmet, eye protection and protective clothing.WHAT CAN HAPPENOperating 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 pro...

21 SAFETY Operator Safety POTENTIAL HAZARDOperating the ATV after consuming alcohol or drugs.WHAT CAN HAPPENConsumption 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 b...

23 SAFETY Operator Safety POTENTIAL HAZARDFailure to inspect the ATV before operating.Failure to properly maintain the ATV.WHAT CAN HAPPENPoor maintenance increases the possibility of an accident or equipment damage.HOW TO AVOID THE HAZARDAlways inspect your ATV before each use to make sure it’s in ...

24 SAFETY Operator Safety POTENTIAL HAZARDFailure to use extra caution when operating the ATV on unfamiliar terrain.WHAT CAN HAPPENUnfamiliar terrain may contain hidden rocks, bumps, or holes that could cause loss of control or overturn.HOW TO AVOID THE HAZARDTravel slowly and use extra caution when...

25 SAFETY Operator Safety POTENTIAL HAZARDFailure to use extra caution when operating on excessively rough, slippery or loose terrain.WHAT CAN HAPPENOperating on excessively rough, slippery or loose terrain could cause loss of traction or loss of control, which could result in an accident or overtur...

26 SAFETY Operator Safety POTENTIAL HAZARDTurning improperly.WHAT CAN HAPPENImproper turns could cause loss of control and lead to a collision or overturn.HOW TO AVOID THE HAZARDAlways follow proper procedures for turning as described in the owner’s manual.Practice turning at slow speeds before atte...

27 SAFETY Operator Safety POTENTIAL HAZARDClimbing hills improperly.WHAT CAN HAPPENImproper hill climbing could cause loss of control or overturn.HOW TO AVOID THE HAZARDAlways follow proper procedures for climbing hills as described in the owner’s manual.Always check the terrain carefully before asc...

28 SAFETY Operator Safety POTENTIAL HAZARDTraveling downhill improperly.WHAT CAN HAPPENImproperly descending a hill could cause loss of control or overturn.HOW TO AVOID THE HAZARDAlways follow proper procedures for traveling down hills as described in the owner’s manual. NOTE: A special technique is...

29 SAFETY Operator Safety POTENTIAL HAZARDImproperly crossing hills and turning on hills.WHAT CAN HAPPENImproperly crossing or turning as hills could cause loss of control or overturn.HOW TO AVOID THE HAZARDNever attempt to turn the ATV around on any hill until you’ve mastered the turning technique ...

30 SAFETY Operator Safety POTENTIAL HAZARDStalling, rolling backwards or improperly dismounting while climbing a hill.WHAT CAN HAPPENThe vehicle could overturn.HOW TO AVOID THE HAZARDMaintain steady speed when climbing a hill.If all forward speed is lost:Keep your weight uphill.Apply the brakes.Lock...

31 SAFETY Operator Safety POTENTIAL HAZARDImproperly operating over obstacles.WHAT CAN HAPPENOperating over obstacles could cause loss of control or overturn.HOW TO AVOID THE HAZARDBefore operating in a new area, check for obstacles.Avoid operating over large obstacles such as rocks and fallen trees...

34 SAFETY Operator Safety POTENTIAL HAZARDOverloading the ATV or carrying/towing cargo improperly.WHAT CAN HAPPENOverloading and towing can cause changes in vehicle handling, which could lead to loss of control or an accident.HOW TO AVOID THE HAZARDNever exceed the stated load capacity for this ATV....

36 CONTROLS Engine Electrical Switches Override Switch (1) (Reverse Speed Limiter) - 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 Demand 4 Drive (All Wheel Drive)...

37 CONTROLS Throttle Lever Engine speed and vehicle movement are controlled by pressing the throttle lever (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 reduc...

38 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. Brake Lever The front and rea...

39 CONTROLS Master Cylinder The brake fluid in the master 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. W...

40 CONTROLS Parking Brake Setting the Parking Brake 1. Squeeze and release the brake lever (1) two or three times, then squeeze and hold. 2. Push the park brake lock (2) forward to engage the brake. Release the brake lever. 3. To release the parking brake lock, squeeze and release the brake lever. I...

41 CONTROLS Auxiliary Brake Your Polaris ATV 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 s...

42 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 transpor...

43 CONTROLS Automatic Transmission Gear Selector The transmission gear selector is located on the right side of the vehicle directly above and forward of the engine. It has five positions: high (H), low (L), neutral (N), reverse (R) and park (P).To shift into high or park , you must first depress th...

44 FEATURES All Wheel Drive (AWD) System Polaris 4-wheel drive ATVs are equipped with a unique, Polaris-exclusive, Demand 4 Drive (AWD) system 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 Dema...

45 FEATURES Instrument 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 appro...

46 FEATURES Instrument Cluster Rider Information Center The rider information center is located in the lower portion of the instrument cluster.1. Gear Indicator - As the shift lever is moved, this will indicate the gear the machine is in:H = High RangeL = Low RangeN = NeutralR = ReverseP = ParkE or ...

47 FEATURES Instrument Cluster Rider Information Center The rider information center has 4 standard modes:Mode 1 - OdometerMode 2 - TripmeterMode 3 - Total Service HoursMode 4 - Programmable service intervalThe reverse override button on the left handlebar is also the mode button . NOTE: If using th...

48 FEATURES Instrument Cluster Rider Information Center Mode 4 - 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 turned off. ...

49 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.To enter the diagnostics mode:1. Turn the key switch off and wait 20 seconds. 2. Set the park brake and shift th...

50 OPERATION Fuel Safety 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 well ventilated area. S Do not smoke or allow open flames or sparks in or near the...

51 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 treatme...

52 OPERATION Pre-Ride Inspection 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 opera...

53 OPERATION Starting the Engine Starting a Cold Engine 1. Place the transmission in neutral 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. T...

54 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. 2. Lock the parking brake, turn the fuel tank ...

55 OPERATION Hauling Cargo 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 specified in your owner’s manual and on safety decals.Cargo weight should be evenly d...

57 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. Release the parking brak...

58 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 slig...

59 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...

60 OPERATION Driving Safely Traveling Uphill 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. Remai...

61 OPERATION Driving Safely Sidehilling 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 th...

62 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 ...

63 OPERATION Driving Safely Turning Around on a Hill If the vehicle stalls while climbing a hill, never back it down the hill! One maneuver that can be used when it’s necessary to turn around while climbing a hill is the K-turn:1. Stop and lock the parking brake while keeping body weight uphill.2. L...

64 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 where both ...

65 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. Severe injury or death can result if your vehicle comes in contact with a hidden obstacle. Not all ...

66 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...

67 OPERATION Driving Safely 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 park.3. Set the parking brake.4. Always block the rear wheels on the downhill side. See illustration. 5. Shut o...

68 NOISE EMISSION CONTROL SYSTEM REGULATION 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 eleme...

69 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. Contact your Polaris dealer for more information.Polaris has a wide range of additional accessories available ...

70 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. Item Hours/ Miles Frequency Remarks Brake Syst...

74 MAINTENANCE AND LUBRICATION Periodic Maintenance Record Use the following chart to record periodic maintenance. Maintenance Interval Performed Servicing Date Servicing Dealer or Person Remarks 10 hrs.20 hrs.50 hrs. 100 hrs.

76 MAINTENANCE AND LUBRICATION Lubrication Recommendations NOTE: Hours 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 Chart Key " More often under severe use, ...

78 MAINTENANCE AND LUBRICATION Lubrication Recommendations 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 ...

79 MAINTENANCE AND LUBRICATION Lubrication Recommendations Engine Oil Check The oil dipstick and fill tube 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 and lift the lever lock (1) on the ...

80 MAINTENANCE AND LUBRICATION Lubrication Recommendations Oil and Filter Change 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 drai...

81 MAINTENANCE AND LUBRICATION Lubrication Recommendations Transmission Oil Check The transmission oil fill plug (1) is located on the right side of the machine behind the footwell. The transmission oil level should be checked every six months or 1000 miles (1600 km), whichever comes first. Transmis...

82 MAINTENANCE AND LUBRICATION Lubrication Recommendations Front Gearcase Oil Check 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.1. Position the ATV on a level surface.2. Remove the...

83 MAINTENANCE AND LUBRICATION Lubrication Recommendations Rear Gearcase Oil Check With the ATV on a level surface, remove the fill plug and visually inspect the lubricant level through the fill hole (1). Maintain the oil level with the bottom of the fill plug hole. Rear Gearcase Oil Change 1. Remov...

84 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.The fluid level must be maintained between the minimum and maximum marks on the bott...

85 MAINTENANCE AND LUBRICATION Engine Cooling System Radiator Coolant Level NOTE: This procedure is required only if the cooling system has been drained for maintenance and/or repair. However, if the recovery bottle has run dry, the level in the radiator should be inspected and coolant added if nece...

86 MAINTENANCE AND LUBRICATION Adjustments Front Brake 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 o...

87 MAINTENANCE AND LUBRICATION Adjustments 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 ...

88 MAINTENANCE AND LUBRICATION Adjustments Toe Alignment 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. NOTE: The steering frog can be used as an indicator of whether ...

89 MAINTENANCE AND LUBRICATION Adjustments Steering Assembly The steering 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. Camber and Caster The camber and caster are non-...

90 MAINTENANCE AND LUBRICATION Adjustments Handlebars 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 a...

92 MAINTENANCE AND LUBRICATION 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...

93 MAINTENANCE AND LUBRICATION Adjustments 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.2. Grasp the rear of the side panel near the rear cab. With a quick and firm motion, pull the pa...

94 MAINTENANCE AND LUBRICATION Adjustments Tire Tread Depth Always replace tires when tread depth is worn to 1/8 ″ (.3 cm) or less. See illustration. Wheel Removal 1. Stop the engine, place the transmission in gear and lock the parking brake. 2. Loosen the wheel nuts slightly.3. Elevate the side of ...

95 MAINTENANCE AND LUBRICATION Adjustments Wheel Installation 1. Place the transmission in gear and lock the parking brake. 2. Apply a small amount of red Loctite t (provided with your ATV) to the studs if the nuts are regular nuts. Do not apply Loctite t if the nuts have an attached washer. 3. Plac...

96 MAINTENANCE AND LUBRICATION Filter Systems Air Filter Service 1. Remove the seat, release the clips, and 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 let d...

97 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. Headlight Lamp Replacement 1. Remove the two screws on the lower front corners of the headlight...

98 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....

99 MAINTENANCE AND LUBRICATION Lights 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 wh...

100 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 new headlamp. 4. Install the new headlamp and h...

101 MAINTENANCE AND LUBRICATION Spark Plugs S Use RC7YC spark plugs. S Proper electrode gap is .035 ″ (.90 mm). S Spark plug torque is 14 ft. lbs. (19 Nm). Spark plug condition is indicative of engine operation. The spark plug firing end condition should be read after the engine has been warmed up a...

102 MAINTENANCE AND LUBRICATION Vehicle Immersion 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 airbox for any water and dry it if water is present. Filt...

103 MAINTENANCE AND LUBRICATION Spark Arrestor 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. 2. Place the transmission in neutral and start the engine. 3. Purge carbon from ...

104 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 pin...

105 MAINTENANCE AND LUBRICATION PVT System 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 an...

106 MAINTENANCE AND LUBRICATION Battery Keep the 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 to...

107 MAINTENANCE AND LUBRICATION Battery Battery Removal 1. Remove the strap securing the battery.2. Remove the battery vent tube from the battery.3. Disconnect the black (negative) battery cable first.4. Disconnect the red (positive) battery cable next.5. Lift the battery out of the ATV, being caref...

108 MAINTENANCE AND LUBRICATION Battery Battery Installation and Connections 1. Set the battery in the battery holder.2. Install the battery vent tube. NOTE: It must be free of obstructions and securely installed. If not, battery gases could accumulate and cause an explosion. The tube should be rout...

109 MAINTENANCE AND LUBRICATION Cleaning and Storage See page 117 for the part numbers of Polaris-recommended 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 ...

110 MAINTENANCE AND LUBRICATION Cleaning and Storage See page 117 for the part numbers of Polaris-recommended products. Storage Tips 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 h...

111 MAINTENANCE AND LUBRICATION Cleaning and Storage See page 117 for the part numbers of Polaris-recommended products. 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...

112 MAINTENANCE AND LUBRICATION Cleaning and Storage See page 117 for the part numbers of Polaris-recommended products. Storage Tips Battery Maintenance 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 d...

113 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 ra...

114 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 12.5 VDC Loose battery connections Check a...

115 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 you...

116 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...

117 POLARIS RECOMMENDED PRODUCTS Part No. Description Engine Lubricant 2870791 Fogging Oil (12 oz. Aerosol) 2871721 Polaris Premium Gold Synthetic 2-Cycle Oil (qt.) 2871240 Polaris Premium Gold Synthetic 2-Cycle Oil (2.5 gal.) 2872927 VES Synthetic 2-Cycle Oil (qt.) 2871098 Premium 2 Cycle Engine Oi...

118 SPECIFICATIONS SPORTSMAN 600 Gross Vehicle Weight 1240 lbs/563kgs Fuel Capacity 4.75 gallons/17.98 liters Towing Capacity 1500 lbs/681 kgs Hitch Tongue Capacity 150 lbs/68.1 kgs (Rear rack capacity and tongue weight not to exceed 200 lbs/90.7 kgs) Front Rack Capacity 100 lbs/45.4 kgs Rear Rack C...

119 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 ...

122 WARRANTY LIMITED WARRANTY Polaris Industries 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 ...

124 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 ...

125 INDEX A Accessories 69 . . . . . . . . . . . . . . . . . . . Adjustments 86-95 . . . . . . . . . . . . . . . . Age Restrictions 11 . . . . . . . . . . . . . . . Air Filter Service 96 . . . . . . . . . . . . . . . All Wheel Drive 44 . . . . . . . . . . . . . . . Automatic Transmission 43 . . . . ...

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. Part No. 9918213 Rev 02 PRINTED IN THE USA...

4 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 e...

5 TABLE OF CONTENTS WELCOME 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . VEHICLE IDENTIFICATION NUMBERS 4 . . . . . . . . . . . . . . . TABLE OF CONTENTS 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SAFETY 6 . . . . . . . . . . . . . . . . . . . . ...

6 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 P...

8 SAFETY Safety Decals and Locations 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 d...

10 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 injur...

11 SAFETY Operator Safety 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. Rea...

12 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, a...

13 SAFETY Operator Safety 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. Contact an authorized Polaris ATV dealer or...

15 SAFETY Operator 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 operat- ing in reverse. When it’s safe to ...

16 SAFETY Operator Safety POTENTIAL HAZARDOperating this ATV without proper instruction.WHAT CAN HAPPENThe 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 HAZARDBeginning...

17 SAFETY Operator Safety POTENTIAL HAZARDCarrying a passenger on an ATV.WHAT CAN HAPPENCarrying 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 HAZARDNever carry a passenger...

18 SAFETY Operator Safety POTENTIAL HAZARDOperating an ATV on paved surfaces, including sidewalks, paths, parking lots, and driveways.WHAT CAN HAPPENATV 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, ...

19 SAFETY Operator Safety POTENTIAL HAZARDOperating this ATV on public streets, roads or highways.WHAT CAN HAPPENThe ATV could collide with another vehicle.HOW TO AVOID THE HAZARDNever operate the ATV on any public street, road or highway, including dirt and gravel roads. In many states it’s illegal...

20 SAFETY Operator Safety POTENTIAL HAZARDOperating this ATV without wearing an approved helmet, eye protection and protective clothing.WHAT CAN HAPPENOperating 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 pro...

21 SAFETY Operator Safety POTENTIAL HAZARDOperating the ATV after consuming alcohol or drugs.WHAT CAN HAPPENConsumption 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 b...

23 SAFETY Operator Safety POTENTIAL HAZARDFailure to inspect the ATV before operating.Failure to properly maintain the ATV.WHAT CAN HAPPENPoor maintenance increases the possibility of an accident or equipment damage.HOW TO AVOID THE HAZARDAlways inspect your ATV before each use to make sure it’s in ...

24 SAFETY Operator Safety POTENTIAL HAZARDFailure to use extra caution when operating the ATV on unfamiliar terrain.WHAT CAN HAPPENUnfamiliar terrain may contain hidden rocks, bumps, or holes that could cause loss of control or overturn.HOW TO AVOID THE HAZARDTravel slowly and use extra caution when...

25 SAFETY Operator Safety POTENTIAL HAZARDFailure to use extra caution when operating on excessively rough, slippery or loose terrain.WHAT CAN HAPPENOperating on excessively rough, slippery or loose terrain could cause loss of traction or loss of control, which could result in an accident or overtur...

26 SAFETY Operator Safety POTENTIAL HAZARDTurning improperly.WHAT CAN HAPPENImproper turns could cause loss of control and lead to a collision or overturn.HOW TO AVOID THE HAZARDAlways follow proper procedures for turning as described in the owner’s manual.Practice turning at slow speeds before atte...

27 SAFETY Operator Safety POTENTIAL HAZARDClimbing hills improperly.WHAT CAN HAPPENImproper hill climbing could cause loss of control or overturn.HOW TO AVOID THE HAZARDAlways follow proper procedures for climbing hills as described in the owner’s manual.Always check the terrain carefully before asc...

28 SAFETY Operator Safety POTENTIAL HAZARDTraveling downhill improperly.WHAT CAN HAPPENImproperly descending a hill could cause loss of control or overturn.HOW TO AVOID THE HAZARDAlways follow proper procedures for traveling down hills as described in the owner’s manual. NOTE: A special technique is...

29 SAFETY Operator Safety POTENTIAL HAZARDImproperly crossing hills and turning on hills.WHAT CAN HAPPENImproperly crossing or turning as hills could cause loss of control or overturn.HOW TO AVOID THE HAZARDNever attempt to turn the ATV around on any hill until you’ve mastered the turning technique ...

30 SAFETY Operator Safety POTENTIAL HAZARDStalling, rolling backwards or improperly dismounting while climbing a hill.WHAT CAN HAPPENThe vehicle could overturn.HOW TO AVOID THE HAZARDMaintain steady speed when climbing a hill.If all forward speed is lost:Keep your weight uphill.Apply the brakes.Lock...

31 SAFETY Operator Safety POTENTIAL HAZARDImproperly operating over obstacles.WHAT CAN HAPPENOperating over obstacles could cause loss of control or overturn.HOW TO AVOID THE HAZARDBefore operating in a new area, check for obstacles.Avoid operating over large obstacles such as rocks and fallen trees...

34 SAFETY Operator Safety POTENTIAL HAZARDOverloading the ATV or carrying/towing cargo improperly.WHAT CAN HAPPENOverloading and towing can cause changes in vehicle handling, which could lead to loss of control or an accident.HOW TO AVOID THE HAZARDNever exceed the stated load capacity for this ATV....

36 CONTROLS Engine Electrical Switches Override Switch (1) (Reverse Speed Limiter) - 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 Demand 4 Drive (All Wheel Drive)...

37 CONTROLS Throttle Lever Engine speed and vehicle movement are controlled by pressing the throttle lever (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 reduc...

38 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. Brake Lever The front and rea...

39 CONTROLS Master Cylinder The brake fluid in the master 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. W...

40 CONTROLS Parking Brake Setting the Parking Brake 1. Squeeze and release the brake lever (1) two or three times, then squeeze and hold. 2. Push the park brake lock (2) forward to engage the brake. Release the brake lever. 3. To release the parking brake lock, squeeze and release the brake lever. I...

41 CONTROLS Auxiliary Brake Your Polaris ATV 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 s...

42 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 transpor...

43 CONTROLS Automatic Transmission Gear Selector The transmission gear selector is located on the right side of the vehicle directly above and forward of the engine. It has five positions: high (H), low (L), neutral (N), reverse (R) and park (P).To shift into high or park , you must first depress th...

44 FEATURES All Wheel Drive (AWD) System Polaris 4-wheel drive ATVs are equipped with a unique, Polaris-exclusive, Demand 4 Drive (AWD) system 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 Dema...

45 FEATURES Instrument 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 appro...

46 FEATURES Instrument Cluster Rider Information Center The rider information center is located in the lower portion of the instrument cluster.1. Gear Indicator - As the shift lever is moved, this will indicate the gear the machine is in:H = High RangeL = Low RangeN = NeutralR = ReverseP = ParkE or ...

47 FEATURES Instrument Cluster Rider Information Center The rider information center has 4 standard modes:Mode 1 - OdometerMode 2 - TripmeterMode 3 - Total Service HoursMode 4 - Programmable service intervalThe reverse override button on the left handlebar is also the mode button . NOTE: If using th...

48 FEATURES Instrument Cluster Rider Information Center Mode 4 - 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 turned off. ...

49 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.To enter the diagnostics mode:1. Turn the key switch off and wait 20 seconds. 2. Set the park brake and shift th...

50 OPERATION Fuel Safety 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 well ventilated area. S Do not smoke or allow open flames or sparks in or near the...

51 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 treatme...

52 OPERATION Pre-Ride Inspection 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 opera...

53 OPERATION Starting the Engine Starting a Cold Engine 1. Place the transmission in neutral 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. T...

54 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. 2. Lock the parking brake, turn the fuel tank ...

55 OPERATION Hauling Cargo 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 specified in your owner’s manual and on safety decals.Cargo weight should be evenly d...

57 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. Release the parking brak...

58 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 slig...

59 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...

60 OPERATION Driving Safely Traveling Uphill 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. Remai...

61 OPERATION Driving Safely Sidehilling 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 th...

62 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 ...

63 OPERATION Driving Safely Turning Around on a Hill If the vehicle stalls while climbing a hill, never back it down the hill! One maneuver that can be used when it’s necessary to turn around while climbing a hill is the K-turn:1. Stop and lock the parking brake while keeping body weight uphill.2. L...

64 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 where both ...

65 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. Severe injury or death can result if your vehicle comes in contact with a hidden obstacle. Not all ...

66 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...

67 OPERATION Driving Safely 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 park.3. Set the parking brake.4. Always block the rear wheels on the downhill side. See illustration. 5. Shut o...

68 NOISE EMISSION CONTROL SYSTEM REGULATION 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 eleme...

69 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. Contact your Polaris dealer for more information.Polaris has a wide range of additional accessories available ...

70 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. Item Hours/ Miles Frequency Remarks Brake Syst...

74 MAINTENANCE AND LUBRICATION Periodic Maintenance Record Use the following chart to record periodic maintenance. Maintenance Interval Performed Servicing Date Servicing Dealer or Person Remarks 10 hrs.20 hrs.50 hrs. 100 hrs.

76 MAINTENANCE AND LUBRICATION Lubrication Recommendations NOTE: Hours 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 Chart Key " More often under severe use, ...

78 MAINTENANCE AND LUBRICATION Lubrication Recommendations 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 ...

79 MAINTENANCE AND LUBRICATION Lubrication Recommendations Engine Oil Check The oil dipstick and fill tube 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 and lift the lever lock (1) on the ...

80 MAINTENANCE AND LUBRICATION Lubrication Recommendations Oil and Filter Change 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 drai...

81 MAINTENANCE AND LUBRICATION Lubrication Recommendations Transmission Oil Check The transmission oil fill plug (1) is located on the right side of the machine behind the footwell. The transmission oil level should be checked every six months or 1000 miles (1600 km), whichever comes first. Transmis...

82 MAINTENANCE AND LUBRICATION Lubrication Recommendations Front Gearcase Oil Check 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.1. Position the ATV on a level surface.2. Remove the...

83 MAINTENANCE AND LUBRICATION Lubrication Recommendations Rear Gearcase Oil Check With the ATV on a level surface, remove the fill plug and visually inspect the lubricant level through the fill hole (1). Maintain the oil level with the bottom of the fill plug hole. Rear Gearcase Oil Change 1. Remov...

84 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.The fluid level must be maintained between the minimum and maximum marks on the bott...

85 MAINTENANCE AND LUBRICATION Engine Cooling System Radiator Coolant Level NOTE: This procedure is required only if the cooling system has been drained for maintenance and/or repair. However, if the recovery bottle has run dry, the level in the radiator should be inspected and coolant added if nece...

86 MAINTENANCE AND LUBRICATION Adjustments Front Brake 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 o...

87 MAINTENANCE AND LUBRICATION Adjustments 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 ...

88 MAINTENANCE AND LUBRICATION Adjustments Toe Alignment 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. NOTE: The steering frog can be used as an indicator of whether ...

89 MAINTENANCE AND LUBRICATION Adjustments Steering Assembly The steering 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. Camber and Caster The camber and caster are non-...

90 MAINTENANCE AND LUBRICATION Adjustments Handlebars 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 a...

92 MAINTENANCE AND LUBRICATION 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...

93 MAINTENANCE AND LUBRICATION Adjustments 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.2. Grasp the rear of the side panel near the rear cab. With a quick and firm motion, pull the pa...

94 MAINTENANCE AND LUBRICATION Adjustments Tire Tread Depth Always replace tires when tread depth is worn to 1/8 ″ (.3 cm) or less. See illustration. Wheel Removal 1. Stop the engine, place the transmission in gear and lock the parking brake. 2. Loosen the wheel nuts slightly.3. Elevate the side of ...

95 MAINTENANCE AND LUBRICATION Adjustments Wheel Installation 1. Place the transmission in gear and lock the parking brake. 2. Apply a small amount of red Loctite t (provided with your ATV) to the studs if the nuts are regular nuts. Do not apply Loctite t if the nuts have an attached washer. 3. Plac...

96 MAINTENANCE AND LUBRICATION Filter Systems Air Filter Service 1. Remove the seat, release the clips, and 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 let d...

97 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. Headlight Lamp Replacement 1. Remove the two screws on the lower front corners of the headlight...

98 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....

99 MAINTENANCE AND LUBRICATION Lights 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 wh...

100 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 new headlamp. 4. Install the new headlamp and h...

101 MAINTENANCE AND LUBRICATION Spark Plugs S Use RC7YC spark plugs. S Proper electrode gap is .035 ″ (.90 mm). S Spark plug torque is 14 ft. lbs. (19 Nm). Spark plug condition is indicative of engine operation. The spark plug firing end condition should be read after the engine has been warmed up a...

102 MAINTENANCE AND LUBRICATION Vehicle Immersion 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 airbox for any water and dry it if water is present. Filt...

103 MAINTENANCE AND LUBRICATION Spark Arrestor 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. 2. Place the transmission in neutral and start the engine. 3. Purge carbon from ...

104 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 pin...

105 MAINTENANCE AND LUBRICATION PVT System 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 an...

106 MAINTENANCE AND LUBRICATION Battery Keep the 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 to...

107 MAINTENANCE AND LUBRICATION Battery Battery Removal 1. Remove the strap securing the battery.2. Remove the battery vent tube from the battery.3. Disconnect the black (negative) battery cable first.4. Disconnect the red (positive) battery cable next.5. Lift the battery out of the ATV, being caref...

108 MAINTENANCE AND LUBRICATION Battery Battery Installation and Connections 1. Set the battery in the battery holder.2. Install the battery vent tube. NOTE: It must be free of obstructions and securely installed. If not, battery gases could accumulate and cause an explosion. The tube should be rout...

109 MAINTENANCE AND LUBRICATION Cleaning and Storage See page 117 for the part numbers of Polaris-recommended 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 ...

110 MAINTENANCE AND LUBRICATION Cleaning and Storage See page 117 for the part numbers of Polaris-recommended products. Storage Tips 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 h...

111 MAINTENANCE AND LUBRICATION Cleaning and Storage See page 117 for the part numbers of Polaris-recommended products. 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...

112 MAINTENANCE AND LUBRICATION Cleaning and Storage See page 117 for the part numbers of Polaris-recommended products. Storage Tips Battery Maintenance 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 d...

113 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 ra...

114 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 12.5 VDC Loose battery connections Check a...

115 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 you...

116 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...

117 POLARIS RECOMMENDED PRODUCTS Part No. Description Engine Lubricant 2870791 Fogging Oil (12 oz. Aerosol) 2871721 Polaris Premium Gold Synthetic 2-Cycle Oil (qt.) 2871240 Polaris Premium Gold Synthetic 2-Cycle Oil (2.5 gal.) 2872927 VES Synthetic 2-Cycle Oil (qt.) 2871098 Premium 2 Cycle Engine Oi...

118 SPECIFICATIONS SPORTSMAN 600 Gross Vehicle Weight 1240 lbs/563kgs Fuel Capacity 4.75 gallons/17.98 liters Towing Capacity 1500 lbs/681 kgs Hitch Tongue Capacity 150 lbs/68.1 kgs (Rear rack capacity and tongue weight not to exceed 200 lbs/90.7 kgs) Front Rack Capacity 100 lbs/45.4 kgs Rear Rack C...

119 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 ...

122 WARRANTY LIMITED WARRANTY Polaris Industries 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 ...

124 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 ...

125 INDEX A Accessories 69 . . . . . . . . . . . . . . . . . . . Adjustments 86-95 . . . . . . . . . . . . . . . . Age Restrictions 11 . . . . . . . . . . . . . . . Air Filter Service 96 . . . . . . . . . . . . . . . All Wheel Drive 44 . . . . . . . . . . . . . . . Automatic Transmission 43 . . . . ...

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. Part No. 9918213 Rev 02 PRINTED IN THE USA...