Polaris Sportsman S - Manuals

4 VEHICLE IDENTIFICATION NUMBERS The frame vehicle identification number (VIN)(1) and engine serial number (2) are important for model identification when registering your vehicle, when obtaining insurance, and when ordering replacement parts. In the event your vehicle is stolen, these numbers are e...

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

6 SAFETY Safety Decals and Locations Warning decals have been placed on the ATV for your protection. Read and follow the instructions on each decal carefully. If a decal becomes illegible or comes off, contact your Polaris dealer to purchase a replacement. Replacement safety decals are provided by P...

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 Moving parts hazard under belt-clutch guard. To prevent serious injury, do not operate vehicle with guard removed.Do not modify engine or clutch. Doing so can cause part failure, possible imbalance, and excessive engine RPM which can result in serious injury or d...

10 SAFETY Safe Riding Gear Always wear clothing suited to the type of riding. ATV riding requires special protective clothing for comfort and to reduce the chance of injury. 1. Helmet Your helmet is the most important piece of protective gear for safe riding. A helmet can prevent a severe head injur...

11 SAFETY Operator Safety Age Restrictions This vehicle is an ADULT VEHICLE ONLY. Operation is prohibited for anyone under 16 years of age. Know Your Vehicle As the operator of the vehicle, you are responsible for your personal safety, the safety of others, and the protection of our environment. Rea...

12 SAFETY Operator Safety The following two pages identify signal words and symbols that appear in this manual. Your safety is involved when these words and symbols are used. Become familiar with their meanings before reading the manual. The safety alert symbol , on your vehicle or in this manual, a...

13 SAFETY Operator Safety S Read this manual and all labels carefully, and follow the operating procedures described. S Never operate an ATV without proper instruction. Take a training course . Beginners should receive training from a certified instructor. Contact an authorized Polaris ATV dealer or...

15 SAFETY Operator Safety S Wet brakes may have reduced stopping ability. Test the brakes after leaving water. If necessary, apply them lightly several times to allow friction to dry out the pads. S Always check for obstacles or people behind the ATV before operat- ing in reverse. When it’s safe to ...

36 CONTROLS Engine Electrical Switches Mode/Reverse Override Switch (1) - This vehicle is equipped with a reverse speed limiter system. To gain additional power while backing, depress the override switch. NOTE: The override switch also allows activation of All Wheel Drive (AWD) in reverse, if the AW...

37 CONTROLS Throttle Lever Engine speed and vehicle movement are controlled by pressing the throttle lever (1). The throttle lever is spring loaded. Engine speed returns to idle when the lever is released.This ATV is equipped with Polaris Electronic Throttle Control (ETC), which is designed to reduc...

38 CONTROLS Light Switches The light switch is located on the left handlebar. It’s used to turn the lights on and off and to switch the lights from HI to LO. NOTE: The lights won’t work unless the key is in the ON position and the shut-off switch is in the RUN position. Brake Lever The front and rea...

39 CONTROLS Master Cylinder The brake fluid in the master cylinder (1), which is located on the left handlebar, should be checked before each ride. The fluid level can be seen through an indicator window (2) on the top of the master cylinder. This eye will appear dark when the fluid level is full. W...

40 CONTROLS Parking Brake Setting the Parking Brake 1. Place the transmission in first gear (or in PARK if equipped). 2. Squeeze and release the brake lever (1) two or three times, then squeeze and hold. 3. Push the park brake lock (2) forward to engage the brake. Release the brake lever. 4. To rele...

41 CONTROLS Auxiliary Brake Your Polaris ATV has an auxiliary brake (1) for added safety. It’s located on the inside of the right floor board and is operated by the right foot. The auxiliary brake serves as a backup to the main brake system if the main system becomes inoperative.If the rear wheels s...

42 CONTROLS Choke The choke assists in starting a cold engine. Refer to the engine starting procedure on page 53 for correct choke and throttle settings during starting. Fuel Valve The fuel valve (1) is located on the left side panel. It has three positions:OFF: For vehicle storage and when transpor...

43 CONTROLS Automatic Transmission Gear Selector The transmission gear selector (1) is located on the right side of the vehicle. Shift patterns vary, depending on your model.H: High Gear L: Low Gear N: Neutral R: Reverse P: Park (Sportsman 600/700 only)To shift into HIGH or PARK on the Sportsman 600...

44 FEATURES All Wheel Drive (AWD) System Polaris 4-wheel drive ATVs are equipped with a unique, Polaris-exclusive, AWD system, which is activated by a switch (1) on the right handlebar. When the switch is off, the ATV is in 2 wheel drive at all times. When the switch is on, the ATV is in AWD and the...

45 FEATURES Instrument Cluster Your ATV is equipped with an instrument cluster that senses vehicle speed from the right front wheel. The instrument cluster measures distance in miles as well as hours of operation. It also includes a reverse speed limiter function that limits the ATV’s speed to appro...

46 FEATURES Instrument Cluster Rider Information Center The rider information center is located in the 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 ...

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

48 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, ei...

50 OPERATION Fuel Safety Gasoline is highly flammable and explosive under certain conditions. S Always exercise extreme caution whenever handling gasoline. S Always refuel with the engine stopped, and outdoors or in a well ventilated area. S Do not smoke or allow open flames or sparks in or near the...

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

52 OPERATION Pre-Ride Inspection Use the following checklist to verify that your vehicle is in proper working condition before each use. Item/Inspection Procedure 1. Tires - Check condition and pressures.2. Fuel tank and engine oil level - Fill both to their proper levels.3. All brakes - Check opera...

53 OPERATION Starting the Engine Starting a Cold Engine 1. Place the transmission in neutral (or PARK if equipped) and lock the parking brake. 2. Turn the fuel tank valve on.3. Sit on the vehicle and pull the choke knob out until it stops (1). NOTE: The variable choke is fully on when the knob is pu...

54 OPERATION Starting the Engine Starting a Warm Engine Warm engines do not normally require the use of the choke. Using the choke can cause the spark plug to become wet fouled.1. Position the vehicle on a level surface with the transmission in neutral (or PARK if equipped). 2. Lock the parking brak...

55 OPERATION Hauling Cargo Your ATV has been designed to carry or tow a certain amount of load. Always read and understand the load distribution warning labels on the vehicle, and never exceed the weight capacities outlined in the specifications section of the owner’s manual and on the safety decals...

57 OPERATION Driving Safely Driving Procedures 1. Sit upright with both feet on the footrests and both hands on the handlebars. 2. Start the engine and allow it to warm up, then shift the transmission into gear. 3. Check your surroundings and determine your path of travel.4. Release the parking brak...

58 OPERATION Driving Safely Making Turns Your ATV is equipped with a solid rear axle, which drives both rear wheels equally at all times. This means that the wheel on the outside of the turn must travel a greater distance than the inside wheel when turning and the inside tire must slip traction slig...

59 OPERATION Driving Safely Driving on Slippery Surfaces Whenever riding on slippery surfaces such as wet trails or loose gravel, or during freezing weather, follow these precautions:1. Slow down when entering slippery areas.2. Maintain a high level of alertness, reading the trail and avoiding quick...

60 OPERATION Driving Safely Traveling Uphill Whenever traveling uphill, follow these precautions:1. Always travel straight uphill.2. Avoid steep hills (25 _ maximum). 3. Keep both feet on the footrests.4. Transfer your weight forward.5. Proceed at a steady rate of speed and throttle opening.6. Remai...

61 OPERATION Driving Safely Sidehilling Sidehilling can be a dangerous type of driving and should be avoided if at all possible. If you do enter into a situation where sidehilling is necessary, follow these precautions:1. Slow down.2. Lean into the hill, transferring your upper body weight toward th...

62 OPERATION Driving Safely Traveling Downhill Whenever descending a hill, follow these precautions:1. Proceed directly downhill.2. Transfer your weight to the rear of the vehicle.3. Slow down.4. Apply the brakes slightly to aid in slowing. Familiarize yourself with operation of the auxiliary brake ...

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

64 OPERATION Driving Safely Driving Through Water Your ATV can operate through water with a maximum recommended depth equal to the bottom of the footrests (1). Follow these procedures when operating through water:1. Determine water depths and current before crossing. 2. Choose a crossing where both ...

65 OPERATION Driving Safely Driving Over Obstacles Be alert! Look ahead and learn to read the terrain you’re traveling on. Be constantly alert for hazards such as logs, rocks and low hanging branches. Severe injury or death can result if your vehicle comes in contact with a hidden obstacle. Not all ...

66 OPERATION Driving Safely Driving in Reverse Follow these precautions when operating in reverse:1. Always avoid backing downhill.2. Back slowly.3. When in reverse, apply the brakes lightly for stopping. 4. Avoid turning at sharp angles in reverse. 5. Never open the throttle suddenly while backing....

67 OPERATION Driving Safely Parking on an Incline Avoid parking on an incline if possible. If it’s unavoidable, follow these precautions:1. Turn the engine off.2. Place the transmission in low range (or park if equipped).3. Set the parking brake.4. Always block the rear wheels on the downhill side a...

68 EMISSION CONTROL SYSTEMS Noise Emission Control System TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED!U.S. Federal law prohibits the following acts or the causing thereof:(1) the removal or rendering inoperative by any person other than for purposes of maintenance, repair, or replacement of any d...

69 MAINTENANCE AND LUBRICATION Periodic Maintenance Schedule Careful periodic maintenance will help keep your vehicle in the safest, most reliable condition. Inspection, adjustment and lubrication of important components are explained in the periodic maintenance schedule. Use the instrument cluster’...

70 MAINTENANCE AND LUBRICATION Periodic Maintenance Schedule Hours of operation are based on a 10 mph average. If service is due at 20 hours, the equivalent odometer reading would be 200 miles. Perform all services at whichever reading is reached first. Item Hours/ Miles Frequency Remarks Brake Syst...

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

76 MAINTENANCE AND LUBRICATION Lubrication Guide NOTE: Hours in the frequency column are based on 10 mph average. If service is due at 20 hours, the equivalent odometer reading would be 200 miles. Perform all services at whichever reading is reached first. Lubrication Guide Key " More often unde...

78 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...

79 MAINTENANCE AND LUBRICATION Oil Check The oil dipstick and fill tube (1) are located on the left side of the vehicle. 1. Position the ATV on a level surface.2. Start the engine and let it idle for 20-30 seconds. 3. Stop the engine. Remove the dipstick and wipe it dry with a clean cloth. NOTE: If ...

80 MAINTENANCE AND LUBRICATION Oil and Filter Change The recommended oil change interval is 100 hours, 1000 miles, or every six months, whichever comes first. Suggested break-in oil change is at 20 hours, 200 miles, or one month, whichever comes first. Severe use operation requires more frequent ser...

88 MAINTENANCE AND LUBRICATION Engine Cooling System Coolant Level The recovery bottle (1) is located on the left side of the machine. To access the recovery bottle, remove the left side panel as outlined on page 93.The fluid level must be maintained between the minimum and maximum marks on the bott...

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

90 MAINTENANCE AND LUBRICATION Front Brake The front brakes are hydraulic disc brakes. They’re activated by moving the brake lever toward the handlebar. These brakes are self-adjusting.The following checks are recommended to keep the brake system in good operating condition. Check more often if brak...

91 MAINTENANCE AND LUBRICATION Rear Brake The rear brake is a hydraulic disc brake and is activated by the same lever that activates the front brake system. The rear brake system is self-adjusting and requires no maintenance other than periodic checks of the pads for wear.Pads should be changed when...

92 MAINTENANCE AND LUBRICATION Toe Alignment Use the following procedure to check the toe alignment of the vehicle. The recommended toe alignment is 1/8 ″ to 1/4 ″ toe out. 1. Set the handlebars in a straight-ahead position. NOTE: The steering frog can be used as an indicator of whether the handleba...

93 MAINTENANCE AND LUBRICATION Side Panel Removal NOTE: Side panel removal may be difficult until the locking tabs and receivers have been snapped and unsnapped a few times.1. Remove the seat.2. Grasp the rear of the side panel near the rear cab. With a quick and firm motion, pull the panel forward ...

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

95 MAINTENANCE AND LUBRICATION Wheel Installation 1. Place the transmission in gear (or in PARK if equipped) and lock the parking brake. 2. Place the wheel on the wheel hub with the valve stem toward the outside and rotation arrows on the tire pointing toward forward rotation. 3. Install the wheel n...

96 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...

97 MAINTENANCE AND LUBRICATION Lights When servicing a halogen lamp, don’t touch the lamp with bare fingers. Oil from your skin leaves a residue, causing a hot spot that will shorten the life of the lamp. Headlight Lamp Replacement 1. Remove the two screws on the lower front corners of the headlight...

98 MAINTENANCE AND LUBRICATION Lights High Beam Adjustment The headlight beam can be adjusted to any position desired by turning the adjusting knob on the bottom right side of the headlight pod.1. Position the vehicle on a level surface with the headlight approximately 25 ft. (7.6 m) from a wall. 2....

99 MAINTENANCE AND LUBRICATION Lights Headlight Housing Replacement 1. Remove the two screws on the lower front corners of the headlight pod. 2. Using a small flat-blade screwdriver, push in on the lock tab through the two small openings at the front of the headlight pod. 3. Lift the pod slightly wh...

100 MAINTENANCE AND LUBRICATION Lights Lower Headlamp Removal / Installation 1. Turn the back of the headlight harness (1) in a clockwise direction. 2. Pull the harness assembly out from the headlight assembly. 3. Remove the headlamp and replace with a new headlamp. 4. Install the new headlamp and h...

101 MAINTENANCE AND LUBRICATION Spark Plugs S Use BKR5E spark plugs for the Sportsman 400 and 500. S Use RC7YC spark plugs for the Sportsman 600 and 700. S Proper electrode gap is .035 ″ (.90 mm). S Spark plug torque is 18 ft. lbs. (24 Nm). Spark plug condition is indicative of engine operation. The...

102 MAINTENANCE AND LUBRICATION Vehicle Immersion If it’s impossible to take your ATV to a dealer before starting it, follow the steps outlined below.1. Move the ATV to dry land or at the very least, to water below the footrests. 2. Check the air box for any water and dry it if water is present. Fil...

103 MAINTENANCE AND LUBRICATION Spark Arrestor Use the following procedure to periodically purge accumulated carbon from the exhaust pipe/muffler.1. Remove the arrestor clean-out plug (1) from the bottom of the muffler. 2. Place the transmission in neutral (or PARK, if equipped) and start the engine...

104 MAINTENANCE AND LUBRICATION PVT System The basic operation of the Polaris PVT system is dependent on engine speed and vehicle torque requirements. As engine speed increases, the force exerted on the movable drive sheave by the flyweights also increases. This, in turn, increases the amount of pin...

105 MAINTENANCE AND LUBRICATION PVT System PVT Drying There may be some instances when water is accidently ingested into the PVT system. Use the following instructions to dry it out before operating:1. Remove the drain plug and allow the water to drain. Replace the drain plug. 2. Start the engine an...

106 MAINTENANCE AND LUBRICATION Battery Your ATV may have either a sealed battery, which requires little maintenance, or a conventional battery. Keep the conventional battery terminals and connections free of corrosion. If cleaning is necessary, remove the corrosion with a stiff wire brush. Wash wit...

107 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...

108 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 ...

109 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...

110 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...

111 MAINTENANCE AND LUBRICATION Cleaning and Storage Storage Tips Clean the Exterior Make necessary repairs and then clean the ATV thoroughly with mild soap and warm water to remove all dirt and grime. Don’t use harsh detergents or high pressure washers. Some detergents deteriorate rubber parts. Use...

112 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...

113 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...

114 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...

116 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...

117 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...

118 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...

119 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...

120 TROUBLESHOOTING Engine Stops or Loses Power Possible Cause Solution Out of fuel Turn fuel valve to reserve, refuel Kinked or plugged fuel vent line Inspect and replace Water present in fuel Replace with new fuel Overuse of choke Inspect, clean and/or replace spark plugs Fouled or defective spark...

121 POLARIS PRODUCTS Part No. Description Engine Lubricant 2870791 Fogging Oil (12 oz. Aerosol) 2871281 Engine Oil (qt.) Premium 4 Synthetic 0W-40 (4-Cycle) 2871844 Engine Oil (gal.) Premium 4 Synthetic 0W-40 (4-Cycle) Gearcase / Transmission Lubricants 2871477 Premium Synthetic Gearcase Lubricant (...

122 SPECIFICATIONS SPORTSMAN 400 Gross Vehicle Weight 1200 lbs./544 kg Towing Capacity 1225 lbs./556 kg Hitch Tongue Capacity 120 lbs./54 kg (Rear rack weight and tongue weight not to exceed 180 lbs./81.6 kg) Front Rack Capacity 90 lbs./40.8 kg Rear Rack Capacity 180 lbs./81.6 kg Overall Length 81 i...

123 SPECIFICATIONS SPORTSMAN 400 Shift Type Side Lever (High, Low, Neutral, Reverse) Gear Reduction - Low 8.27/1 Gear Reduction - Reverse 5.17/1 Gear Reduction - Forward 3.34/1 Drive Ratio - Front 2:1 Drive Ratio - Final 3.16:1 Tire, Front 25 x 8 - 12 (5 psi) Tire, Rear 25 x 11 - 12 (5 psi) Front Br...

125 SPECIFICATIONS SPORTSMAN 500 Driving System Type EBS Shift Type Side Lever (High, Low, Neutral, Reverse) Gear Reduction - Low 8.27/1 Gear Reduction - Reverse 5.17/1 Gear Reduction - Forward 3.34/1 Drive Ratio - Front 2:1 Drive Ratio - Final 3.16:1 Tire, Front 25 x 8 - 12 (5 psi) Tire, Rear 25 x ...

127 SPECIFICATIONS SPORTSMAN 600 Shift Type Side Lever (High, Low, Neutral, Reverse, Park) Gear Reduction - Low 7.5/1 Gear Reduction - Reverse 5.11/1 Gear Reduction - High 3.09/1 Drive Ratio - Front: 3.82/1 Drive Ratio - Final 3.10/1 Tire Size - Front 25 x 8 - 12 Tire Size - Rear 25 x 11 - 12 Front ...

129 SPECIFICATIONS SPORTSMAN 700 Shift Type Side Lever (High, Low, Neutral, Reverse, Park) Gear Reduction - Low 7.5/1 Gear Reduction - Reverse 5.11/1 Gear Reduction - High 2.89/1 Drive Ratio - Front: 3.82/1 Drive Ratio - Final 3.10/1 Tire Size - Front 25 x 8 - 12 Tire Size - Rear 25 x 11 - 12 Front ...

130 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...

132 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 ...

133 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...

134 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...

135 INDEX A Accessories 110 . . . . . . . . . . . . . . . . . . . . ADJUSTMENTS 114-116 . . . . . . . . . . . Age Restrictions 11 . . . . . . . . . . . . . . . . . Air Filter Service 96 . . . . . . . . . . . . . . . . All Wheel Drive 44 . . . . . . . . . . . . . . . . . Automatic Transmission 43 . ....

Part No. 9918540 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 ...

4 VEHICLE IDENTIFICATION NUMBERS The frame vehicle identification number (VIN)(1) and engine serial number (2) are important for model identification when registering your vehicle, when obtaining insurance, and when ordering replacement parts. In the event your vehicle is stolen, these numbers are e...

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

6 SAFETY Safety Decals and Locations Warning decals have been placed on the ATV for your protection. Read and follow the instructions on each decal carefully. If a decal becomes illegible or comes off, contact your Polaris dealer to purchase a replacement. Replacement safety decals are provided by P...

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 Moving parts hazard under belt-clutch guard. To prevent serious injury, do not operate vehicle with guard removed.Do not modify engine or clutch. Doing so can cause part failure, possible imbalance, and excessive engine RPM which can result in serious injury or d...

10 SAFETY Safe Riding Gear Always wear clothing suited to the type of riding. ATV riding requires special protective clothing for comfort and to reduce the chance of injury. 1. Helmet Your helmet is the most important piece of protective gear for safe riding. A helmet can prevent a severe head injur...

11 SAFETY Operator Safety Age Restrictions This vehicle is an ADULT VEHICLE ONLY. Operation is prohibited for anyone under 16 years of age. Know Your Vehicle As the operator of the vehicle, you are responsible for your personal safety, the safety of others, and the protection of our environment. Rea...

12 SAFETY Operator Safety The following two pages identify signal words and symbols that appear in this manual. Your safety is involved when these words and symbols are used. Become familiar with their meanings before reading the manual. The safety alert symbol , on your vehicle or in this manual, a...

13 SAFETY Operator Safety S Read this manual and all labels carefully, and follow the operating procedures described. S Never operate an ATV without proper instruction. Take a training course . Beginners should receive training from a certified instructor. Contact an authorized Polaris ATV dealer or...

15 SAFETY Operator Safety S Wet brakes may have reduced stopping ability. Test the brakes after leaving water. If necessary, apply them lightly several times to allow friction to dry out the pads. S Always check for obstacles or people behind the ATV before operat- ing in reverse. When it’s safe to ...

36 CONTROLS Engine Electrical Switches Mode/Reverse Override Switch (1) - This vehicle is equipped with a reverse speed limiter system. To gain additional power while backing, depress the override switch. NOTE: The override switch also allows activation of All Wheel Drive (AWD) in reverse, if the AW...

37 CONTROLS Throttle Lever Engine speed and vehicle movement are controlled by pressing the throttle lever (1). The throttle lever is spring loaded. Engine speed returns to idle when the lever is released.This ATV is equipped with Polaris Electronic Throttle Control (ETC), which is designed to reduc...

38 CONTROLS Light Switches The light switch is located on the left handlebar. It’s used to turn the lights on and off and to switch the lights from HI to LO. NOTE: The lights won’t work unless the key is in the ON position and the shut-off switch is in the RUN position. Brake Lever The front and rea...

39 CONTROLS Master Cylinder The brake fluid in the master cylinder (1), which is located on the left handlebar, should be checked before each ride. The fluid level can be seen through an indicator window (2) on the top of the master cylinder. This eye will appear dark when the fluid level is full. W...

40 CONTROLS Parking Brake Setting the Parking Brake 1. Place the transmission in first gear (or in PARK if equipped). 2. Squeeze and release the brake lever (1) two or three times, then squeeze and hold. 3. Push the park brake lock (2) forward to engage the brake. Release the brake lever. 4. To rele...

41 CONTROLS Auxiliary Brake Your Polaris ATV has an auxiliary brake (1) for added safety. It’s located on the inside of the right floor board and is operated by the right foot. The auxiliary brake serves as a backup to the main brake system if the main system becomes inoperative.If the rear wheels s...

42 CONTROLS Choke The choke assists in starting a cold engine. Refer to the engine starting procedure on page 53 for correct choke and throttle settings during starting. Fuel Valve The fuel valve (1) is located on the left side panel. It has three positions:OFF: For vehicle storage and when transpor...

43 CONTROLS Automatic Transmission Gear Selector The transmission gear selector (1) is located on the right side of the vehicle. Shift patterns vary, depending on your model.H: High Gear L: Low Gear N: Neutral R: Reverse P: Park (Sportsman 600/700 only)To shift into HIGH or PARK on the Sportsman 600...

44 FEATURES All Wheel Drive (AWD) System Polaris 4-wheel drive ATVs are equipped with a unique, Polaris-exclusive, AWD system, which is activated by a switch (1) on the right handlebar. When the switch is off, the ATV is in 2 wheel drive at all times. When the switch is on, the ATV is in AWD and the...

45 FEATURES Instrument Cluster Your ATV is equipped with an instrument cluster that senses vehicle speed from the right front wheel. The instrument cluster measures distance in miles as well as hours of operation. It also includes a reverse speed limiter function that limits the ATV’s speed to appro...

46 FEATURES Instrument Cluster Rider Information Center The rider information center is located in the 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 ...

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

48 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, ei...

50 OPERATION Fuel Safety Gasoline is highly flammable and explosive under certain conditions. S Always exercise extreme caution whenever handling gasoline. S Always refuel with the engine stopped, and outdoors or in a well ventilated area. S Do not smoke or allow open flames or sparks in or near the...

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

52 OPERATION Pre-Ride Inspection Use the following checklist to verify that your vehicle is in proper working condition before each use. Item/Inspection Procedure 1. Tires - Check condition and pressures.2. Fuel tank and engine oil level - Fill both to their proper levels.3. All brakes - Check opera...

53 OPERATION Starting the Engine Starting a Cold Engine 1. Place the transmission in neutral (or PARK if equipped) and lock the parking brake. 2. Turn the fuel tank valve on.3. Sit on the vehicle and pull the choke knob out until it stops (1). NOTE: The variable choke is fully on when the knob is pu...

54 OPERATION Starting the Engine Starting a Warm Engine Warm engines do not normally require the use of the choke. Using the choke can cause the spark plug to become wet fouled.1. Position the vehicle on a level surface with the transmission in neutral (or PARK if equipped). 2. Lock the parking brak...

55 OPERATION Hauling Cargo Your ATV has been designed to carry or tow a certain amount of load. Always read and understand the load distribution warning labels on the vehicle, and never exceed the weight capacities outlined in the specifications section of the owner’s manual and on the safety decals...

57 OPERATION Driving Safely Driving Procedures 1. Sit upright with both feet on the footrests and both hands on the handlebars. 2. Start the engine and allow it to warm up, then shift the transmission into gear. 3. Check your surroundings and determine your path of travel.4. Release the parking brak...

58 OPERATION Driving Safely Making Turns Your ATV is equipped with a solid rear axle, which drives both rear wheels equally at all times. This means that the wheel on the outside of the turn must travel a greater distance than the inside wheel when turning and the inside tire must slip traction slig...

59 OPERATION Driving Safely Driving on Slippery Surfaces Whenever riding on slippery surfaces such as wet trails or loose gravel, or during freezing weather, follow these precautions:1. Slow down when entering slippery areas.2. Maintain a high level of alertness, reading the trail and avoiding quick...

60 OPERATION Driving Safely Traveling Uphill Whenever traveling uphill, follow these precautions:1. Always travel straight uphill.2. Avoid steep hills (25 _ maximum). 3. Keep both feet on the footrests.4. Transfer your weight forward.5. Proceed at a steady rate of speed and throttle opening.6. Remai...

61 OPERATION Driving Safely Sidehilling Sidehilling can be a dangerous type of driving and should be avoided if at all possible. If you do enter into a situation where sidehilling is necessary, follow these precautions:1. Slow down.2. Lean into the hill, transferring your upper body weight toward th...

62 OPERATION Driving Safely Traveling Downhill Whenever descending a hill, follow these precautions:1. Proceed directly downhill.2. Transfer your weight to the rear of the vehicle.3. Slow down.4. Apply the brakes slightly to aid in slowing. Familiarize yourself with operation of the auxiliary brake ...

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

64 OPERATION Driving Safely Driving Through Water Your ATV can operate through water with a maximum recommended depth equal to the bottom of the footrests (1). Follow these procedures when operating through water:1. Determine water depths and current before crossing. 2. Choose a crossing where both ...

65 OPERATION Driving Safely Driving Over Obstacles Be alert! Look ahead and learn to read the terrain you’re traveling on. Be constantly alert for hazards such as logs, rocks and low hanging branches. Severe injury or death can result if your vehicle comes in contact with a hidden obstacle. Not all ...

66 OPERATION Driving Safely Driving in Reverse Follow these precautions when operating in reverse:1. Always avoid backing downhill.2. Back slowly.3. When in reverse, apply the brakes lightly for stopping. 4. Avoid turning at sharp angles in reverse. 5. Never open the throttle suddenly while backing....

67 OPERATION Driving Safely Parking on an Incline Avoid parking on an incline if possible. If it’s unavoidable, follow these precautions:1. Turn the engine off.2. Place the transmission in low range (or park if equipped).3. Set the parking brake.4. Always block the rear wheels on the downhill side a...

68 EMISSION CONTROL SYSTEMS Noise Emission Control System TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED!U.S. Federal law prohibits the following acts or the causing thereof:(1) the removal or rendering inoperative by any person other than for purposes of maintenance, repair, or replacement of any d...

69 MAINTENANCE AND LUBRICATION Periodic Maintenance Schedule Careful periodic maintenance will help keep your vehicle in the safest, most reliable condition. Inspection, adjustment and lubrication of important components are explained in the periodic maintenance schedule. Use the instrument cluster’...

70 MAINTENANCE AND LUBRICATION Periodic Maintenance Schedule Hours of operation are based on a 10 mph average. If service is due at 20 hours, the equivalent odometer reading would be 200 miles. Perform all services at whichever reading is reached first. Item Hours/ Miles Frequency Remarks Brake Syst...

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

76 MAINTENANCE AND LUBRICATION Lubrication Guide NOTE: Hours in the frequency column are based on 10 mph average. If service is due at 20 hours, the equivalent odometer reading would be 200 miles. Perform all services at whichever reading is reached first. Lubrication Guide Key " More often unde...

78 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...

79 MAINTENANCE AND LUBRICATION Oil Check The oil dipstick and fill tube (1) are located on the left side of the vehicle. 1. Position the ATV on a level surface.2. Start the engine and let it idle for 20-30 seconds. 3. Stop the engine. Remove the dipstick and wipe it dry with a clean cloth. NOTE: If ...

80 MAINTENANCE AND LUBRICATION Oil and Filter Change The recommended oil change interval is 100 hours, 1000 miles, or every six months, whichever comes first. Suggested break-in oil change is at 20 hours, 200 miles, or one month, whichever comes first. Severe use operation requires more frequent ser...

88 MAINTENANCE AND LUBRICATION Engine Cooling System Coolant Level The recovery bottle (1) is located on the left side of the machine. To access the recovery bottle, remove the left side panel as outlined on page 93.The fluid level must be maintained between the minimum and maximum marks on the bott...

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

90 MAINTENANCE AND LUBRICATION Front Brake The front brakes are hydraulic disc brakes. They’re activated by moving the brake lever toward the handlebar. These brakes are self-adjusting.The following checks are recommended to keep the brake system in good operating condition. Check more often if brak...

91 MAINTENANCE AND LUBRICATION Rear Brake The rear brake is a hydraulic disc brake and is activated by the same lever that activates the front brake system. The rear brake system is self-adjusting and requires no maintenance other than periodic checks of the pads for wear.Pads should be changed when...

92 MAINTENANCE AND LUBRICATION Toe Alignment Use the following procedure to check the toe alignment of the vehicle. The recommended toe alignment is 1/8 ″ to 1/4 ″ toe out. 1. Set the handlebars in a straight-ahead position. NOTE: The steering frog can be used as an indicator of whether the handleba...

93 MAINTENANCE AND LUBRICATION Side Panel Removal NOTE: Side panel removal may be difficult until the locking tabs and receivers have been snapped and unsnapped a few times.1. Remove the seat.2. Grasp the rear of the side panel near the rear cab. With a quick and firm motion, pull the panel forward ...

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

95 MAINTENANCE AND LUBRICATION Wheel Installation 1. Place the transmission in gear (or in PARK if equipped) and lock the parking brake. 2. Place the wheel on the wheel hub with the valve stem toward the outside and rotation arrows on the tire pointing toward forward rotation. 3. Install the wheel n...

96 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...

97 MAINTENANCE AND LUBRICATION Lights When servicing a halogen lamp, don’t touch the lamp with bare fingers. Oil from your skin leaves a residue, causing a hot spot that will shorten the life of the lamp. Headlight Lamp Replacement 1. Remove the two screws on the lower front corners of the headlight...

98 MAINTENANCE AND LUBRICATION Lights High Beam Adjustment The headlight beam can be adjusted to any position desired by turning the adjusting knob on the bottom right side of the headlight pod.1. Position the vehicle on a level surface with the headlight approximately 25 ft. (7.6 m) from a wall. 2....

99 MAINTENANCE AND LUBRICATION Lights Headlight Housing Replacement 1. Remove the two screws on the lower front corners of the headlight pod. 2. Using a small flat-blade screwdriver, push in on the lock tab through the two small openings at the front of the headlight pod. 3. Lift the pod slightly wh...

100 MAINTENANCE AND LUBRICATION Lights Lower Headlamp Removal / Installation 1. Turn the back of the headlight harness (1) in a clockwise direction. 2. Pull the harness assembly out from the headlight assembly. 3. Remove the headlamp and replace with a new headlamp. 4. Install the new headlamp and h...

101 MAINTENANCE AND LUBRICATION Spark Plugs S Use BKR5E spark plugs for the Sportsman 400 and 500. S Use RC7YC spark plugs for the Sportsman 600 and 700. S Proper electrode gap is .035 ″ (.90 mm). S Spark plug torque is 18 ft. lbs. (24 Nm). Spark plug condition is indicative of engine operation. The...

102 MAINTENANCE AND LUBRICATION Vehicle Immersion If it’s impossible to take your ATV to a dealer before starting it, follow the steps outlined below.1. Move the ATV to dry land or at the very least, to water below the footrests. 2. Check the air box for any water and dry it if water is present. Fil...

103 MAINTENANCE AND LUBRICATION Spark Arrestor Use the following procedure to periodically purge accumulated carbon from the exhaust pipe/muffler.1. Remove the arrestor clean-out plug (1) from the bottom of the muffler. 2. Place the transmission in neutral (or PARK, if equipped) and start the engine...

104 MAINTENANCE AND LUBRICATION PVT System The basic operation of the Polaris PVT system is dependent on engine speed and vehicle torque requirements. As engine speed increases, the force exerted on the movable drive sheave by the flyweights also increases. This, in turn, increases the amount of pin...

105 MAINTENANCE AND LUBRICATION PVT System PVT Drying There may be some instances when water is accidently ingested into the PVT system. Use the following instructions to dry it out before operating:1. Remove the drain plug and allow the water to drain. Replace the drain plug. 2. Start the engine an...

106 MAINTENANCE AND LUBRICATION Battery Your ATV may have either a sealed battery, which requires little maintenance, or a conventional battery. Keep the conventional battery terminals and connections free of corrosion. If cleaning is necessary, remove the corrosion with a stiff wire brush. Wash wit...

107 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...

108 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 ...

109 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...

110 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...

111 MAINTENANCE AND LUBRICATION Cleaning and Storage Storage Tips Clean the Exterior Make necessary repairs and then clean the ATV thoroughly with mild soap and warm water to remove all dirt and grime. Don’t use harsh detergents or high pressure washers. Some detergents deteriorate rubber parts. Use...

112 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...

113 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...

114 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...

116 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...

117 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...

118 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...

119 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...

120 TROUBLESHOOTING Engine Stops or Loses Power Possible Cause Solution Out of fuel Turn fuel valve to reserve, refuel Kinked or plugged fuel vent line Inspect and replace Water present in fuel Replace with new fuel Overuse of choke Inspect, clean and/or replace spark plugs Fouled or defective spark...

121 POLARIS PRODUCTS Part No. Description Engine Lubricant 2870791 Fogging Oil (12 oz. Aerosol) 2871281 Engine Oil (qt.) Premium 4 Synthetic 0W-40 (4-Cycle) 2871844 Engine Oil (gal.) Premium 4 Synthetic 0W-40 (4-Cycle) Gearcase / Transmission Lubricants 2871477 Premium Synthetic Gearcase Lubricant (...

122 SPECIFICATIONS SPORTSMAN 400 Gross Vehicle Weight 1200 lbs./544 kg Towing Capacity 1225 lbs./556 kg Hitch Tongue Capacity 120 lbs./54 kg (Rear rack weight and tongue weight not to exceed 180 lbs./81.6 kg) Front Rack Capacity 90 lbs./40.8 kg Rear Rack Capacity 180 lbs./81.6 kg Overall Length 81 i...

123 SPECIFICATIONS SPORTSMAN 400 Shift Type Side Lever (High, Low, Neutral, Reverse) Gear Reduction - Low 8.27/1 Gear Reduction - Reverse 5.17/1 Gear Reduction - Forward 3.34/1 Drive Ratio - Front 2:1 Drive Ratio - Final 3.16:1 Tire, Front 25 x 8 - 12 (5 psi) Tire, Rear 25 x 11 - 12 (5 psi) Front Br...

125 SPECIFICATIONS SPORTSMAN 500 Driving System Type EBS Shift Type Side Lever (High, Low, Neutral, Reverse) Gear Reduction - Low 8.27/1 Gear Reduction - Reverse 5.17/1 Gear Reduction - Forward 3.34/1 Drive Ratio - Front 2:1 Drive Ratio - Final 3.16:1 Tire, Front 25 x 8 - 12 (5 psi) Tire, Rear 25 x ...

127 SPECIFICATIONS SPORTSMAN 600 Shift Type Side Lever (High, Low, Neutral, Reverse, Park) Gear Reduction - Low 7.5/1 Gear Reduction - Reverse 5.11/1 Gear Reduction - High 3.09/1 Drive Ratio - Front: 3.82/1 Drive Ratio - Final 3.10/1 Tire Size - Front 25 x 8 - 12 Tire Size - Rear 25 x 11 - 12 Front ...

129 SPECIFICATIONS SPORTSMAN 700 Shift Type Side Lever (High, Low, Neutral, Reverse, Park) Gear Reduction - Low 7.5/1 Gear Reduction - Reverse 5.11/1 Gear Reduction - High 2.89/1 Drive Ratio - Front: 3.82/1 Drive Ratio - Final 3.10/1 Tire Size - Front 25 x 8 - 12 Tire Size - Rear 25 x 11 - 12 Front ...

130 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...

132 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 ...

133 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...

134 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...

135 INDEX A Accessories 110 . . . . . . . . . . . . . . . . . . . . ADJUSTMENTS 114-116 . . . . . . . . . . . Age Restrictions 11 . . . . . . . . . . . . . . . . . Air Filter Service 96 . . . . . . . . . . . . . . . . All Wheel Drive 44 . . . . . . . . . . . . . . . . . Automatic Transmission 43 . ....

Part No. 9918540 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 ...