Page 2 - PRINTED IN THE USA; WARNING; Improper vehicle use can result in SEVERE INJURY or DEATH.
Part No. 9919412 Rev 04 PRINTED IN THE USA WARNING Improper vehicle use can result in SEVERE INJURY or DEATH. READ OWNER'S MANUAL. FOLLOW ALL INSTRUCTIONS AND WARNINGS. ALWAYS USE AN APPROVED HELMET AND PROTECTIVE GEAR NEVER USE ON PUBLIC ROADS NEVER CARRY PASSENGERS NEVER USE WITH DRUGS OR ALCOHOL ...
Page 3 - to the owner’s manual on the next page. If you cannot locate this card,; The engine exhaust from this
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. The engine exhaust from this product contains chemicals known to cause cancer, birth def...
Page 6 - WELCOME; Polaris Recreational Vehicles; RANGER
3 WELCOME Thank you for purchasing a Polaris vehicle, and welcome to our world-wide family of Polaris owners. We proudly produce an exciting line of utility and recreational products. Polaris Recreational Vehicles S Snowmobiles S All-terrain vehicles (ATVs) S Watercraft S RANGER utility vehicles S V...
Page 8 - TABLE OF CONTENTS
5 TABLE OF CONTENTS WELCOME 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . VEHICLE IDENTIFICATION NUMBERS 7 . . . . . . . . . . . SAFETY 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CONTROLS 33 . . . . . . . . . . . . . . . . . . . . . . . ...
Page 10 - VEHICLE IDENTIFICATION NUMBERS; Record your ATV’s identification numbers and key number in the
7 VEHICLE IDENTIFICATION NUMBERS Record your ATV’s identification numbers and key number in the spaces provided. 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, so if both keys are lost, the ignition swi...
Page 11 - SAFETY; Safety Decals and Locations; ATV, always read and follow the instructions of the decals
8 SAFETY Safety Decals and Locations Warning decals have been placed on the ATV for your protection. Read and follow the instructions of the decals on the ATV carefully. If any of the decals depicted in this manual differ from the decals on your ATV, always read and follow the instructions of the de...
Page 12 - ATTENTION
9 SAFETY Safety Decals and Locations IMPROPER TIRE PRESSURE OR OVERLOADING can cause loss of control resulting in SEVERE INJURY OR DEATH. TIRE PRESSURE IN PSI (KPa): FRONT 5 (34,5) REAR 5 (34,5) M AXIMUM WEIGHT CAPACITY (Gross Vehicle Weight) INCLUDING MACHINE, DRIVER AND CARGO IS 1200 LBS. (545 kg)...
Page 13 - NO STEP
10 SAFETY Safety Decals and Locations 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 100 lbs. (45 kg) Rear 200 lbs. (91 kg) 7172749 S DO NOT TOW FROM RACK OR BUMPER. Vehicle damage or ti...
Page 15 - Safe Riding Gear
12 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...
Page 16 - Operator Safety; vehicle handles differently than other vehicles, such as; Age Restrictions
13 SAFETY Operator Safety WARNING Failure to follow the warnings contained in this manual can result in serious 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 ...
Page 17 - are used. Become familiar with their meanings before reading the; safety alert symbol; safety alert warning; safety alert caution; CAUTION; caution
14 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...
Page 18 - Serious injury or death can result if you do not follow these; Take a training
15 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...
Page 20 - FOR MORE INFORMATION ABOUT ATV SAFETY, call the Con-; Equipment Modifications; The addition of certain accessories, including (but not limited
17 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 ...
Page 21 - not know how to operate the ATV properly in different situations; abilities, or judgment needed to operate an ATV safely and could
18 SAFETY Operator Safety WARNING 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 HAZARDB...
Page 24 - could seriously affect operator; visibility and operating conditions, and your experience.
21 SAFETY Operator Safety WARNING 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...
Page 25 - the chance of an accident,; schedules described in the owner’s manual.
22 SAFETY Operator Safety WARNING POTENTIAL HAZARDAttempting wheelies, jumps and other stunts.WHAT CAN HAPPENAttempting stunts increases the chance of an accident, including an overturn.HOW TO AVOID THE HAZARDNever attempt wheelies, jumps, or other stunts. Avoid exhibition driving. WARNING POTENTIAL...
Page 27 - caution when operating on
24 SAFETY Operator Safety WARNING 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...
Page 30 - turning as hills could cause
27 SAFETY Operator Safety WARNING 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 te...
Page 31 - or improperly dismounting
28 SAFETY Operator Safety WARNING 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 bra...
Page 32 - trees when possible. If unavoidable, use extreme caution and; caution to reduce the chance of skidding or sliding out of control.; people behind the ATV. When it’s safe to proceed, back slowly.
29 SAFETY Operator Safety WARNING 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 fall...
Page 33 - unavoidable to enter water that exceeds the recommended
30 SAFETY Operator Safety WARNING POTENTIAL HAZARDOperating the ATV through deep or fast-flowing water.WHAT CAN HAPPENTires may float, causing loss of traction and loss of control, which could lead to an accident or overturn.HOW TO AVOID THE HAZARDAvoid operating the ATV through deep or fast-flowing...
Page 34 - accessories. All parts and accessories added to the vehicle must
31 SAFETY Operator Safety WARNING POTENTIAL HAZARDOperating the ATV with improper modifications.WHAT CAN HAPPENImproper installation of accessories or modification of the ATV may cause changes in handling which could lead to an accident.HOW TO AVOID THE HAZARDNever modify the ATV through improper in...
Page 36 - CONTROLS; Engine Electrical Switches; OFF
33 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. Mode/Reverse Override Switch (1) - This vehicle is equipped with a ...
Page 37 - Throttle Lever
34 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.Fa...
Page 38 - Light Switches; ON; Brake Lever
35 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 ...
Page 39 - Master Cylinder; eye
36 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...
Page 40 - Parking Brake; Operating the ATV while the parking brake is engaged could; Setting the Parking Brake
37 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. Place the transmission in PARK.2. Squeeze and release...
Page 41 - Auxiliary Brake; Aggressively applying the auxiliary brake when backing down a; reduce; Brake Fluid Level
38 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 wheel...
Page 42 - Choke
39 CONTROLS Choke The choke assists in starting a cold engine. Refer to the engine starting procedure on page 50 for correct choke and throttle settings during starting. Fuel Valve The fuel valve (1) is located on the left side panel. It has two positions:OFF: For vehicle storage and when transporti...
Page 43 - Automatic Transmission Gear Selector; to activate the high/park lock-out mechanism. When shifting out of; Shifting gears with the engine speed above idle or while the; PARK and lock the parking brake.; Belt Life
40 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: ParkTo shift into HIGH or PARK, you must first apply the auxiliary brake to ...
Page 44 - FEATURES; The override switch allows activation of AWD in reverse if the; Engaging Front Gearcase; Switching to AWD while the rear wheels are spinning may cause
41 FEATURES All Wheel Drive (AWD) System Polaris 4-wheel drive ATVs are equipped with a unique, Polaris-exclusive, All Wheel Drive (AWD) system, which is activated by a switch (1) on the right handlebar. When the switch is off, the ATV is in 2 wheel drive at all times. When the switch is on, the ATV...
Page 45 - Instrument Cluster; speed from the right front wheel. The instrument cluster measures; To prevent damage, wash the ATV by hand or with a garden hose
42 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 or kilometers as well as hours of operation. It also includes a reverse speed limiter function that limits the ATV’s ...
Page 46 - Rider Information Center; If the instrument cluster fails to illuminate, a battery; Engine Hour Display Indicator
43 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 ...
Page 47 - mode
44 FEATURES Instrument Cluster Rider Information Center The rider information center has 4 standard modes:Mode 1 - OdometerMode 2 - TripmeterMode 3 - Total Service HoursMode 4 - TachometerThe reverse override button on the left handlebar is also the mode button . NOTE: If using the mode button to pr...
Page 48 - Diagnostic Mode; Any movement of the tires will also take the machine out of
45 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, tu...
Page 49 - If you scroll past the intended number, hold the button down
46 FEATURES Instrument Cluster Rider Information Center Diagnostic Mode Screen 5: Programmable service interval The purpose of the programmable service interval is to provide the consumer and dealer with a convenient reminder for routine maintenance. When your vehicle leaves the factory, this featur...
Page 50 - OPERATION; Fuel Safety
47 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 well ventilated area. S Do not smoke or allow open flames or sparks in or ...
Page 51 - the procedures for a proper break-in. Careful treatment of a new; SH; oil if necessary to maintain the level between the safe and add
48 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...
Page 52 - If a proper inspection is not done before each use, severe injury
49 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. Pre-Ride Checklist Item Remarks See Page Brake system / lever travel Ensure prope...
Page 53 - Starting the Engine; Starting a Cold Engine
50 OPERATION Starting the Engine 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 PARK and lock the parking brake. 2. Turn th...
Page 54 - Starting a Warm Engine; immediately; Cold Weather Operation
51 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 PARK. 2. Lock the parking brake, turn the fuel tank val...
Page 55 - Driving Safely; Hauling Cargo; Your ATV has been designed to carry or tow a certain amount of load.; Use low forward gear when hauling or towing heavy cargo to extend
52 OPERATION Driving Safely 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 outlined in the specifications section of the owner’s manual and on th...
Page 57 - Driving Procedures
54 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...
Page 58 - Making Turns; Practice making turns at slow speeds before attempting to; Turning at sharp angles or at excessive speeds can result in
55 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...
Page 59 - Driving on Slippery Surfaces
56 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. Engage AWD before wheels begin to lose traction. 3. Maintain a high lev...
Page 60 - Driving Uphill; include quick dismounting of the vehicle.; terrain. Improper procedure could cause loss of control or
57 OPERATION Driving Safely Driving 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. Remain ...
Page 61 - Sidehilling; control or vehicle overturn, resulting in severe injury or death.; hill while keeping your feet on the footrests.; If the vehicle begins to tip, quickly turn the front wheel
58 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. Sidehilli...
Page 62 - Driving Downhill; slightly; Excessive speed can cause loss of control and lead to serious
59 OPERATION Driving Safely Driving 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...
Page 63 - Turning Around on a Hill; Improper hill climbing procedures could cause loss of control or; slowly
60 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 ...
Page 64 - Driving Through Water; critical
61 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 ...
Page 65 - Driving Over Obstacles; Be constantly alert for hazards such as logs, rocks and low hanging; Severe injury or death can result if your vehicle comes in contact
62 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. ...
Page 66 - Driving in Reverse; apply the brakes
63 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...
Page 67 - Parking on an Incline; Avoid parking on an incline if possible. If it’s unavoidable, follow
64 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 as shown in the illustration...
Page 68 - EMISSION CONTROL SYSTEMS; Noise Emission Control System; Do not modify the engine, intake or exhaust components, as doing so; Crankcase Emission Control System; This engine is equipped with a closed crankcase system. Blow–by; Exhaust Emission Control System; The installation of devices that effectively increase exhaust; Spark Arrestor; in accordance with the USDA Forest Service Standard 5100–1C. Fed-; Electromagnetic Interference
65 EMISSION CONTROL SYSTEMS Noise Emission Control System Do not modify the engine, intake or exhaust components, as doing so may affect compliance with state and local noise level requirements. Crankcase Emission Control System This engine is equipped with a closed crankcase system. Blow–by gases a...
Page 69 - MAINTENANCE AND LUBRICATION; Accessories; Severe Use Definition; Maintenance Chart Key
66 MAINTENANCE AND LUBRICATION Accessories Auxiliary power outlets provide 12V power for operating accessories such as hand held spot lights. See your Polaris dealer. Periodic Maintenance Chart Careful periodic maintenance will help keep your vehicle in the safest, most reliable condition. Inspectio...
Page 70 - Periodic Maintenance Chart
67 MAINTENANCE AND LUBRICATION Periodic Maintenance Chart Perform all services at whichever maintenance interval is reached first. Item Maintenance Interval (whichever comes first) Remarks Hours Calendar Miles (Km) J Steering -- Pre-Ride -- Make adjustments as need- ed See Pre Ride Checklist " F...
Page 73 - Periodic Maintenance Record; Use the following chart to record periodic maintenance.
70 MAINTENANCE AND LUBRICATION Periodic Maintenance Record Use the following chart to record periodic maintenance. Maintenance Interval Performed Servicing Date Servicing Dealer or Person Remarks
Page 74 - Lubrication Guide; these components are greased “for life” at the factory. No; Lubrication Guide Key; More often under severe use
71 MAINTENANCE AND LUBRICATION Lubrication Guide Check and lubricate all components at the intervals outlined in the Periodic Maintenance Chart beginning on page 66. Items not listed in the chart should be lubricated at the General Lubrication interval. NOTE: The a--arms and lower control arms have ...
Page 75 - Premium 4 Synthetic Lubricant; See page 113 for the part numbers of Polaris products.; Mixing brands or using a non-recommended oil may cause
72 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 a...
Page 76 - Oil Check; upper
1 SAFE ADD 8 OZ 3 4 ADD 8 OZ. NORMAL FULL 4 5 2 73 MAINTENANCE AND LUBRICATION Oil Check The 400/500 oil dipstick and fill tube (1) are located on the left side of the ATV. The 600/700 dipstick/oil fill (2) is located on the engine and is accessible on the left side of the ATV. NOTE: A rising oil le...
Page 77 - Oil and Filter Change
74 MAINTENANCE AND LUBRICATION Oil and Filter Change Change the oil and filter at the intervals outlined in the Periodic Maintenance Chart beginning on page 66. Oil Change (400/500) 1. Position the vehicle on a level surface. Clean the area around the drain plug at the bottom of the oil tank and the...
Page 78 - The sealing surfaces on the; Prime the oil pump using the procedure on page 76.
75 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. A...
Page 79 - Oil Pump Priming; If you do not hear
76 MAINTENANCE AND LUBRICATION Oil Change (400/500) Oil Pump Priming This priming procedure must be performed whenever the oil hose connection between the oil tank and pump inlet has been disconnected.1. Clamp or pinch off the vent line (1) approximately 2 I from the oil tank (2), between the end of...
Page 80 - Hot oil can cause serious burns. Do not allow hot oil to touch
77 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 cau...
Page 82 - Front Gearcase Oil; Premium Demand Drive Hub Fluid
79 MAINTENANCE AND LUBRICATION Front Gearcase Oil Always check and change the front gearcase oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 66. Maintain the oil level even with the bottom of the fill hole threads (1). We recommend the use of Polaris Premium Demand ...
Page 85 - Engine Cooling System; Radiator Coolant Level
82 MAINTENANCE AND LUBRICATION Engine Cooling System Radiator Coolant Level To ensure that the coolant maintains its ability to protect the engine, we recommend that the system be completely drained every two years and a fresh mixture of antifreeze and water added. Polaris recommends the use of Pola...
Page 86 - Coolant Level; Some coolant level drop on new machines is normal, as the
83 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 87.Maintain the coolant level between the minimum and maximum marks on the bottle (when...
Page 87 - Brakes; The front and rear brakes are hydraulic disc brakes, activated by
84 MAINTENANCE AND LUBRICATION Brakes The front and rear brakes are hydraulic disc brakes, activated by moving the single brake lever toward the handlebar. These brakes are self-adjusting.The following checks are recommended to keep the brake system in good operating condition. Check more often if b...
Page 88 - damage and looseness.; Pads should be changed; main brake system. Should the main system fail, the rear brake can be; Since this is a rear brake only, it will not be as effective as
85 MAINTENANCE AND LUBRICATION Brakes 2. Check the brake system for fluid leaks.3. Check the brakes for excessive travel or spongy feel. 4. Check the friction pads for wear, damage and looseness. 5. Check the security and surface condition of the disc. NOTE: Pads should be changed when worn to 3/64 ...
Page 89 - Steering Assembly
86 MAINTENANCE AND LUBRICATION 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. Toe Alignment WARNING Severe injury or death can result from...
Page 90 - Side Panel Removal; motion, pull the panel outward to disengage the side panel from the; Footwell Removal; on the bottom of the footwell.
87 MAINTENANCE AND LUBRICATION Side Panel Removal 1. Remove the seat.2. Grasp the rear of the side panel near the rear cab. With a firm motion, pull the panel outward to disengage the side panel from the grommet. 3. Pull the panel downward and rearward to remove it from the ATV.4. Reinstall the side...
Page 91 - Operating your ATV with worn tires, improperly inflated tires,; Tire Tread Depth
88 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...
Page 92 - Wheel Installation; Place the transmission in; Place the wheel on the wheel hub with the valve stem toward the; Wheel Nut Torque Specifications; Check the wheel nut torques occasionally and when they’ve been
89 MAINTENANCE AND LUBRICATION Wheel Installation 1. Place the transmission in PARK and lock the parking brake. WARNING Improperly installed wheels can adversely affect tire wear and vehicle handling, which can result in serious injury or death. Always ensure that all nuts are torqued to specificati...
Page 93 - Filter Systems; Air Filter Service; It’s not necessary to remove the lower hose from the engine.; Operation of your vehicle without a breather filter can cause
90 MAINTENANCE AND LUBRICATION Filter Systems Air Filter Service 1. Remove the seat, release the air box cover 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 r...
Page 94 - Lights; When servicing a halogen lamp, don’t touch the lamp with bare; Poor lighting while driving can result in severe injury or death.; Headlight Lamp Replacement; Remove the two screws on the lower front corners of the headlight; Make sure the tab on the lamp locates properly in the
91 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. WARNING Poor lighting while driving can result in severe injury or death. Headlight and taillig...
Page 95 - High Beam Adjustment; Include rider weight on the seat when measuring.; Low Beam Adjustment
92 MAINTENANCE AND LUBRICATION Lights High Beam Adjustment The headlight beam can be adjusted slightly upward or downward. Use the following procedure to make the adjustment.1. Position the vehicle on a level surface with the headlight approximately 25 ft. (7.6 m) from a wall. 2. Measure the distanc...
Page 96 - Headlight Housing Replacement; The distance from the; Adjust the headlight aim by
93 MAINTENANCE AND LUBRICATION Lights Headlight Housing Replacement 1. Remove the two screws on the lower front corners of the headlight pod. 2. Lift the pod slightly while depressing the tabs at the rear of the pod. 3. Lift the pod cover and disconnect the speedometer harnesses from the speedometer...
Page 97 - Lower Headlamp Removal / Installation
1 1 2 2 1 94 MAINTENANCE AND LUBRICATION Lights Lower Headlamp Removal / Installation 1. Turn the back of the headlight harness (1) counterclockwise and pull the harness assembly away from the headlight assembly. 2. Remove the headlamp and install the new headlamp. 3. Reinstall the harness assembly ...
Page 98 - Spark Plugs; Spark Plug Removal and Replacement
95 MAINTENANCE AND LUBRICATION Spark Plugs Always use the spark plugs recommended for your ATV. Refer to the specifications section beginning on page 118 for the recommended spark plug type and gap. CAUTION Using non-recommended spark plugs can result in serious engine damage. Always use Polaris-rec...
Page 99 - Vehicle Immersion; If your vehicle becomes immersed, major engine damage can
96 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...
Page 100 - Failure to heed the following warnings while servicing the spark
97 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 componen...
Page 101 - PVT System; pinch; When To Use Low Range vs. High Range; Low Range
98 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 pinc...
Page 102 - PVT Drying; the PVT system. Use the following instructions to dry it out before
99 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 precisio...
Page 103 - Battery; Your ATV may have either a sealed battery, which requires little; Drink large quantities of water or milk. Follow with milk
100 MAINTENANCE AND LUBRICATION Battery Your ATV may have either a sealed battery, which requires little maintenance, or a conventional battery. A sealed battery can be identified by its flat covers on the top of the battery. A conventional battery has six filler caps on the top of the battery.Alway...
Page 104 - Battery Removal; remove battery cover.; Battery Installation
101 MAINTENANCE AND LUBRICATION Battery 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) batt...
Page 105 - Battery Storage; in an explosion and cause serious injury or death. When; fully charged
102 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 ...
Page 106 - charged battery will register 12.8 V or higher.
103 MAINTENANCE AND LUBRICATION Battery Battery Charging (Sealed Battery) For a refresh charge, follow all instructions carefully.1. Check the battery voltage with a voltmeter or multimeter. A fully charged battery will register 12.8 V or higher. 2. If the voltage is less than 12.8 volts, recharge t...
Page 107 - Cleaning the ATV
104 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. Clea...
Page 108 - Cleaning and Storage; Storage Tips; Starting the engine during the storage period will disturb the; Clean the Exterior
105 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 cle...
Page 109 - Fog the Engine; Do this carefully! If you miss the plug hole, oil will drain from; Alternative to Using Fogging Oil
106 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 o...
Page 110 - Do not; Do not use plastic or coated materials. They do not allow
107 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...
Page 111 - Removing Corrosion; Transporting the ATV
108 MAINTENANCE AND LUBRICATION Chrome Wheel Care (if equipped) Proper maintenance will protect chrome wheels from corrosion, preserve wheel life and ensure a “like new” appearance for many years.1. Wash chrome rims frequently. Use a mild detergent to remove any salt, dirt, mud or grime. Never use a...
Page 112 - ADJUSTMENTS; Camber and Caster
109 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 deal...
Page 113 - Continuous operation of the engine without proper jetting
110 ADJUSTMENTS Carburetor/Idle RPM Your Polaris ATV is calibrated at the factory for optimal performance at altitudes ranging from zero to 6,000 feet (1800 m) and temperatures of +40 degrees F. (4 degrees C.) or higher. Above 6000 feet (1800 m) the engine air/fuel mixture becomes overly rich and th...
Page 114 - Throttle Cable Freeplay; freeplay is achieved at the; While adjusting freeplay, be sure to flip the throttle lever back; they touch at the midpoint of the adjuster.
111 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 fre...
Page 115 - NOTES
Page 116 - POLARIS PRODUCTS
113 POLARIS PRODUCTS Part No. Description Engine Lubricant 2870791 Fogging Oil (12 oz. Aerosol) 2871281 Premium 4 Synthetic 0W-40 (4-Cycle) Engine Oil (qt.) 2871844 Premium 4 Synthetic 0W-40 (4-Cycle) Engine Oil (gal.) Gearcase / Transmission Lubricants 2873602 Premium AGL Synthetic Gearcase Lube (q...
Page 117 - TROUBLESHOOTING; Drive Belt and Cover Problems; Possible Cause
114 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...
Page 118 - solutions using the following charts.; Engine Doesn’t Turn Over
115 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...
Page 119 - Engine Backfires
116 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...
Page 120 - Engine Stops or Loses Power; Engine Overheating
117 TROUBLESHOOTING Engine Stops or Loses Power Possible Cause Solution Out of fuel 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...
Page 121 - SPECIFICATIONS
118 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/Storage Box Capacity 90 lbs./40.8 kgRear Rack/Storage Box Capacity 180 lbs./81.6...
Page 122 - Jetting Chart; Clutching Chart
119 SPECIFICATIONS SPORTSMAN 400 Shift Type Side Lever (H/L/N/R/P) Gear Reduction - Low 23.91/1 Gear Reduction - Reverse 16.30/1 Gear Reduction - Forward 10.49/1 Drive Ratio - Front 3.82/1 Tire, Front Polaris PXT 26 x 8 - 12 (5 psi) Tire, Rear Polaris PXT 26 x 11 - 12 (5 psi) Front Brake Single-cont...
Page 124 - *EBS models require no helix / spring adjustment
121 SPECIFICATIONS SPORTSMAN 500 Shift Type Side Lever (H/L/N/R/P) Gear Reduction - Low 23.91/1 Gear Reduction - Reverse 16.30/1 Gear Reduction - Forward 10.49/1 Drive Ratio - Front 3.82/1 Tire, Front Polaris PXT 26 x 8 - 12 (5 psi) Tire, Rear Polaris PXT 26 x 11 - 12 (5 psi) Front Brake Single-cont...
Page 129 - WARRANTY; LIMITED WARRANTY
126 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 f...
Page 131 - HOW TO OBTAIN WARRANTY SERVICE; Engine Oil
128 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 ...
Page 132 - Exported Vehicles; How to Get Service; In the Country where your vehicle was purchased:
129 WARRANTY Exported Vehicles EXCEPT WHERE SPECIFICALLY REQUIRED BY LAW, THERE IS NO WARRANTY OR SERVICE BULLETIN COVERAGE ON THIS VEHICLE IF IT IS SOLD OUTSIDE THE COUNTRY OF THE SELLING DEALER’S AUTHORIZED LOCATION. This policy does not apply to vehicles that have received authorization for expor...
Page 133 - If Purchased From A Private Party:; Notice; chased, and you have not followed the procedure set out above, your
130 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 th...
Page 134 - INDEX
131 INDEX A Accessories 66, 104 . . . . . . . . . . . . . . . ADJUSTMENTS 109-111 . . . . . . . . . . Age Restrictions 13 . . . . . . . . . . . . . . . Air Filter Service 90 . . . . . . . . . . . . . . . All Wheel Drive 41 . . . . . . . . . . . . . . . Automatic Transmission 40 . . . . . . . . . Aux...
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