Polaris Sportsman 450 - Manuals

5 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...

6 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...

7 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)...

8 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 tip...

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 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 ...

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 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...

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 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...

19 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...

20 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...

22 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...

25 SAFETY Operator Safety WARNING POTENTIAL HAZARDImproperly crossing hills and turning on hills.WHAT CAN HAPPENImproperly crossing or turning on 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...

26 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...

27 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...

28 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...

29 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...

31 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 ...

32 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...

33 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 ...

34 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...

35 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...

36 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...

37 CONTROLS Choke The choke assists in starting a cold engine. Refer to the engine starting procedure on page 48 for correct choke and throttle settings during starting. Fuel Valve The fuel valve (1) is located on the bottom of the fuel tank. Access the fuel valve through the right front wheel well....

38 CONTROLS Automatic Transmission Gear Selector The transmission gear selector (1) is located on the right side of the vehicle. Shift patterns vary, depending on your model.H: High Gear L: Low Gear N: Neutral R: Reverse P: Park CAUTION Shifting gears with the engine speed above idle or while the ve...

39 FEATURES All Wheel Drive (AWD) System The All Wheel Drive system is activated by the AWD switch (1) on the right handlebar. When the switch is on 2X4, the ATV is in two-wheel drive at all times. When the switch is on AWD, the ATV is in all wheel drive and the AWD indicator light in the instrument...

40 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 ...

41 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 ...

42 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...

43 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...

44 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...

45 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 ...

46 OPERATION Break-In Period The break-in period for your new Polaris ATV is the first ten hours of operation, or the time it takes to use the first two full tanks of gasoline. No single action on your part is as important as following the procedures for a proper break-in. Careful treatment of a new...

47 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...

48 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...

49 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...

50 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...

52 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...

53 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...

54 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...

55 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 ...

56 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...

57 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...

8’ (2.4 m) 58 OPERATION Driving Safely Turning Around on a Hill If the vehicle stalls while climbing a hill, never back it down the hill! Use the K-turn to turn around. 1. Stop and lock the parking brake while keeping body weight uphill.2. Leave the transmission in forward and shut off the engine.3....

59 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 ...

60 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. ...

61 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...

62 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...

63 EMISSION CONTROL SYSTEMS Noise Emission Control System Do not modify the engine, intake or exhaust components, as doing so may affect compliance with U.S.A. EPA noise control requirements (40 CFR 205) and local noise level requirements. Operation on Public Lands in the U.S.A. Your Polaris vehicle...

64 MAINTENANCE AND LUBRICATION Periodic Maintenance Chart Careful periodic maintenance will help keep your vehicle in the safest, most reliable condition. Inspection, adjustment and lubrication of important components are explained in the periodic maintenance chart.Inspect, clean, lubricate, adjust ...

65 MAINTENANCE AND LUBRICATION Periodic Maintenance Chart Maintenance Chart Key " Perform these procedures more frequently for vehicles subjected to severe use. E Emission-related service (Failure to conduct this maintenance will not void the emissions warranty but may affect emissions.) J Have ...

69 MAINTENANCE AND LUBRICATION Lubrication Guide Check and lubricate all components at the intervals outlined in the Periodic Maintenance Chart beginning on page 64. Items not listed in the chart should be lubricated at the General Lubrication interval. NOTE: The a-arms and lower control arms are lu...

2 1 70 MAINTENANCE AND LUBRICATION Engine Oil Always check and change the engine oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 64. Always change the oil filter whenever changing oil. Premium 4 Synthetic Oil Polaris Premium 4 All Season synthetic engine oil has bee...

SAFE ADD 8 OZ 3 4 ADD 8 OZ. NORMAL FULL 4 5 71 MAINTENANCE AND LUBRICATION Engine Oil Oil Check 2. Sportsman 450/500 only: Start the engine and let it idle for 20-30 seconds. Stop the engine. 3. Remove the dipstick and wipe it dry with a clean cloth. NOTE: If the dipstick is equipped with a lever lo...

72 MAINTENANCE AND LUBRICATION Engine Oil Oil Change (450/500) 1. Position the vehicle on a level surface. Clean the area around the drain plug at the bottom of the oil tank and the bottom of the engine. 2. Run the engine for two to three minutes, then turn it off.3. Place a drain pan beneath the oi...

73 MAINTENANCE AND LUBRICATION Engine Oil Oil Change (450/500) 9. Place shop towels beneath the oil filter. Using an oil filter wrench, turn the filter (1) counterclockwise and remove. 10. Lubricate the gasket on the new filter with a film of new engine oil. Check to make sure the gasket is in good ...

74 MAINTENANCE AND LUBRICATION Engine Oil Oil Change (450/500) 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...

75 MAINTENANCE AND LUBRICATION Engine Oil Oil Change (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 ...

77 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 ...

1 2 79 MAINTENANCE AND LUBRICATION Rear Gearcase Oil (700) The rear gearcase fill plug (1) is located on the rear of the gearcase. The drain plug (2) is on the bottom of the gearcase. Always check and change the rear gearcase oil at the intervals outlined in the Periodic Maintenance Chart beginning ...

80 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...

81 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 85.Maintain the coolant level between the minimum and maximum marks on the bottle (when...

82 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...

83 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 ...

84 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...

85 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...

86 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...

87 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...

88 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...

89 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...

90 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...

91 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...

1 1 2 2 1 92 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 ...

93 MAINTENANCE AND LUBRICATION Spark Plugs Always use the spark plugs recommended for your ATV. Refer to the specifications section beginning on page 116 for the recommended spark plug type and gap. CAUTION Using non-recommended spark plugs can result in serious engine damage. Always use Polaris-rec...

94 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...

95 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...

96 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...

97 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...

98 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.Always...

99 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) batte...

100 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 ...

101 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...

102 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...

103 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...

104 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...

105 MAINTENANCE AND LUBRICATION Cleaning and Storage Storage Tips Inspect and Lubricate Inspect all cables and lubricate. Follow lubrication guidelines in the Maintenance Section of the service or owner’s manual to completely grease and lubricate the entire vehicle with Polaris Premium All Season Gr...

106 MAINTENANCE AND LUBRICATION Transporting the ATV Follow these procedures when transporting the vehicle.1. Turn off the engine and remove the key to prevent loss during transporting. 2. Place the transmission in PARK and lock the parking brake. 3. Turn the fuel valve off and be sure the fuel cap,...

107 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...

108 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...

109 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...

111 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...

112 TROUBLESHOOTING Contact your Polaris dealer for service if you’re unable to identify solutions using the following charts. Drive Belt and Cover Problems Possible Cause Solution Driving onto a pickup or tall trailer in high range Shift transmission to low range during loading of the ATV to preven...

113 TROUBLESHOOTING 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 all connections and tighten Loose solenoid connections Check all connections and tighten Engine Turns Over, ...

114 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...

115 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...

116 SPECIFICATIONS SPORTSMAN 450 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...

117 SPECIFICATIONS SPORTSMAN 450 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 Carlisle AT489 25 x 8 - 12 (5 psi) Tire, Rear Carlisle AT489 25 x 11 - 12 (5 psi) Front Brake Singl...

121 SPECIFICATIONS SPORTSMAN 700 Shift Type Side Lever (H/L/N/R/P) Gear Reduction - Low 7.49/1 Gear Reduction - Reverse 5.11/1 Gear Reduction - High 2.89/1 Drive Ratio - Front 3.82/1 Drive Ratio - Final 3.10/1 Tire Size - Front 26 x 8 - 12 (5 psi) Tire Size - Rear 26 x 11 - 12 (5 psi) Front Brake Si...

122 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...

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 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...

126 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...

128 MAINTENANCE LOG Use the following chart to record periodic maintenance. DATE MILES (KM) TECHNICIAN SERVICE PERFORMED / COMMENTS

130 INDEX A Accessories 102 . . . . . . . . . . . . . . . . . . Age Restrictions 11 . . . . . . . . . . . . . . . Air Filter Service 88 . . . . . . . . . . . . . . . All Wheel Drive 39 . . . . . . . . . . . . . . . Automatic Transmission 38 . . . . . . . . . Auxiliary Brake 83 . . . . . . . . . . . ...

5 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...

6 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...

7 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)...

8 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 tip...

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 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 ...

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 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...

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 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...

19 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...

20 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...

22 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...

25 SAFETY Operator Safety WARNING POTENTIAL HAZARDImproperly crossing hills and turning on hills.WHAT CAN HAPPENImproperly crossing or turning on 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...

26 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...

27 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...

28 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...

29 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...

31 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 ...

32 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...

33 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 ...

34 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...

35 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...

36 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...

37 CONTROLS Choke The choke assists in starting a cold engine. Refer to the engine starting procedure on page 48 for correct choke and throttle settings during starting. Fuel Valve The fuel valve (1) is located on the bottom of the fuel tank. Access the fuel valve through the right front wheel well....

38 CONTROLS Automatic Transmission Gear Selector The transmission gear selector (1) is located on the right side of the vehicle. Shift patterns vary, depending on your model.H: High Gear L: Low Gear N: Neutral R: Reverse P: Park CAUTION Shifting gears with the engine speed above idle or while the ve...

39 FEATURES All Wheel Drive (AWD) System The All Wheel Drive system is activated by the AWD switch (1) on the right handlebar. When the switch is on 2X4, the ATV is in two-wheel drive at all times. When the switch is on AWD, the ATV is in all wheel drive and the AWD indicator light in the instrument...

40 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 ...

41 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 ...

42 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...

43 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...

44 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...

45 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 ...

46 OPERATION Break-In Period The break-in period for your new Polaris ATV is the first ten hours of operation, or the time it takes to use the first two full tanks of gasoline. No single action on your part is as important as following the procedures for a proper break-in. Careful treatment of a new...

47 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...

48 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...

49 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...

50 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...

52 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...

53 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...

54 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...

55 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 ...

56 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...

57 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...

8’ (2.4 m) 58 OPERATION Driving Safely Turning Around on a Hill If the vehicle stalls while climbing a hill, never back it down the hill! Use the K-turn to turn around. 1. Stop and lock the parking brake while keeping body weight uphill.2. Leave the transmission in forward and shut off the engine.3....

59 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 ...

60 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. ...

61 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...

62 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...

63 EMISSION CONTROL SYSTEMS Noise Emission Control System Do not modify the engine, intake or exhaust components, as doing so may affect compliance with U.S.A. EPA noise control requirements (40 CFR 205) and local noise level requirements. Operation on Public Lands in the U.S.A. Your Polaris vehicle...

64 MAINTENANCE AND LUBRICATION Periodic Maintenance Chart Careful periodic maintenance will help keep your vehicle in the safest, most reliable condition. Inspection, adjustment and lubrication of important components are explained in the periodic maintenance chart.Inspect, clean, lubricate, adjust ...

65 MAINTENANCE AND LUBRICATION Periodic Maintenance Chart Maintenance Chart Key " Perform these procedures more frequently for vehicles subjected to severe use. E Emission-related service (Failure to conduct this maintenance will not void the emissions warranty but may affect emissions.) J Have ...

69 MAINTENANCE AND LUBRICATION Lubrication Guide Check and lubricate all components at the intervals outlined in the Periodic Maintenance Chart beginning on page 64. Items not listed in the chart should be lubricated at the General Lubrication interval. NOTE: The a-arms and lower control arms are lu...

2 1 70 MAINTENANCE AND LUBRICATION Engine Oil Always check and change the engine oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 64. Always change the oil filter whenever changing oil. Premium 4 Synthetic Oil Polaris Premium 4 All Season synthetic engine oil has bee...

SAFE ADD 8 OZ 3 4 ADD 8 OZ. NORMAL FULL 4 5 71 MAINTENANCE AND LUBRICATION Engine Oil Oil Check 2. Sportsman 450/500 only: Start the engine and let it idle for 20-30 seconds. Stop the engine. 3. Remove the dipstick and wipe it dry with a clean cloth. NOTE: If the dipstick is equipped with a lever lo...

72 MAINTENANCE AND LUBRICATION Engine Oil Oil Change (450/500) 1. Position the vehicle on a level surface. Clean the area around the drain plug at the bottom of the oil tank and the bottom of the engine. 2. Run the engine for two to three minutes, then turn it off.3. Place a drain pan beneath the oi...

73 MAINTENANCE AND LUBRICATION Engine Oil Oil Change (450/500) 9. Place shop towels beneath the oil filter. Using an oil filter wrench, turn the filter (1) counterclockwise and remove. 10. Lubricate the gasket on the new filter with a film of new engine oil. Check to make sure the gasket is in good ...

74 MAINTENANCE AND LUBRICATION Engine Oil Oil Change (450/500) 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...

75 MAINTENANCE AND LUBRICATION Engine Oil Oil Change (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 ...

77 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 ...

1 2 79 MAINTENANCE AND LUBRICATION Rear Gearcase Oil (700) The rear gearcase fill plug (1) is located on the rear of the gearcase. The drain plug (2) is on the bottom of the gearcase. Always check and change the rear gearcase oil at the intervals outlined in the Periodic Maintenance Chart beginning ...

80 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...

81 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 85.Maintain the coolant level between the minimum and maximum marks on the bottle (when...

82 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...

83 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 ...

84 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...

85 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...

86 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...

87 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...

88 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...

89 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...

90 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...

91 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...

1 1 2 2 1 92 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 ...

93 MAINTENANCE AND LUBRICATION Spark Plugs Always use the spark plugs recommended for your ATV. Refer to the specifications section beginning on page 116 for the recommended spark plug type and gap. CAUTION Using non-recommended spark plugs can result in serious engine damage. Always use Polaris-rec...

94 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...

95 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...

96 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...

97 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...

98 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.Always...

99 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) batte...

100 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 ...

101 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...

102 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...

103 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...

104 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...

105 MAINTENANCE AND LUBRICATION Cleaning and Storage Storage Tips Inspect and Lubricate Inspect all cables and lubricate. Follow lubrication guidelines in the Maintenance Section of the service or owner’s manual to completely grease and lubricate the entire vehicle with Polaris Premium All Season Gr...

106 MAINTENANCE AND LUBRICATION Transporting the ATV Follow these procedures when transporting the vehicle.1. Turn off the engine and remove the key to prevent loss during transporting. 2. Place the transmission in PARK and lock the parking brake. 3. Turn the fuel valve off and be sure the fuel cap,...

107 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...

108 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...

109 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...

111 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...

112 TROUBLESHOOTING Contact your Polaris dealer for service if you’re unable to identify solutions using the following charts. Drive Belt and Cover Problems Possible Cause Solution Driving onto a pickup or tall trailer in high range Shift transmission to low range during loading of the ATV to preven...

113 TROUBLESHOOTING 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 all connections and tighten Loose solenoid connections Check all connections and tighten Engine Turns Over, ...

114 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...

115 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...

116 SPECIFICATIONS SPORTSMAN 450 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...

117 SPECIFICATIONS SPORTSMAN 450 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 Carlisle AT489 25 x 8 - 12 (5 psi) Tire, Rear Carlisle AT489 25 x 11 - 12 (5 psi) Front Brake Singl...

121 SPECIFICATIONS SPORTSMAN 700 Shift Type Side Lever (H/L/N/R/P) Gear Reduction - Low 7.49/1 Gear Reduction - Reverse 5.11/1 Gear Reduction - High 2.89/1 Drive Ratio - Front 3.82/1 Drive Ratio - Final 3.10/1 Tire Size - Front 26 x 8 - 12 (5 psi) Tire Size - Rear 26 x 11 - 12 (5 psi) Front Brake Si...

122 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...

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 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...

126 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...

128 MAINTENANCE LOG Use the following chart to record periodic maintenance. DATE MILES (KM) TECHNICIAN SERVICE PERFORMED / COMMENTS

130 INDEX A Accessories 102 . . . . . . . . . . . . . . . . . . Age Restrictions 11 . . . . . . . . . . . . . . . Air Filter Service 88 . . . . . . . . . . . . . . . All Wheel Drive 39 . . . . . . . . . . . . . . . Automatic Transmission 38 . . . . . . . . . Auxiliary Brake 83 . . . . . . . . . . . ...