Polaris Sprotsman 700 - Manuals

5 TABLE OF CONTENTS Maintenance and Lubrication 82 . . . . . . . . . . . . . . . Periodic Maintenance Schedule 82 . . . . . . . . . . . . . . . . . . Lubrication Recommendations 88 . . . . . . . . . . . . . . . . . . . Maintenance Record 92 . . . . . . . . . . . . . . . . . . . . . . . . . . . Cooli...

6 VEHICLE IDENTIFICATION NUMBERS The frame vehicle identification number (VIN) (1) and engine serialnumber (2) are important for model identification when registeringyour vehicle, when obtaining insurance, and when orderingreplacement parts. If your vehicle is stolen, these numbers are essentialto i...

7 VEHICLE SPECIFICATIONS SPORTSMAN 700 Gross Vehicle Weight 1240 lbs. Fuel Capacity 4.75 U.S. Gallons Towing Capacity 1500 lbs Hitch Tongue Capacity 150 lbs Overall Length 85” Overall Width 46” Overall Height 47” Wheelbase 50.75 Ground Clearance 11” Dry Weight 740 lbs Minimum Turning Radius 71.5” En...

8 VEHICLE 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 F...

9 SAFETY Understanding Warnings The following two pages identify signal words and symbols that appearin this manual. Your safety is involved when these words and symbolsare used. Become familiar with their meanings before reading themanual. The safety alert symbol , on your vehicle or in this manual...

10 SAFETY Key Safety Issues Protect Your Sport Know all local, state/province riding laws;Respect your vehicle;Respect the environment; andYou will gain the respect of others.We also advise you to strictly follow the recommended maintenanceprogram as outlined. This preventive maintenance program is ...

11 SAFETY Key Safety Issues SERIOUS INJURY OR DEATH can result if you do notfollow these instructions: Read this manual and all labels carefully and follow the operating procedures described. Never operate an ATV without proper instruction. Take a training course. Beginners should receive training f...

13 SAFETY Key Safety Issues Always be sure there are no obstacles or people behind you when you operate in reverse. When it is safe to proceed in reverse, goslowly. Avoid turning at sharp angles in reverse. Always use the size and type tires specified in this manual. Always maintain proper tire pres...

14 SAFETY Safety Decals and Locations NOTE: Warning decals have been placed on the vehicle for your protection.Read and follow the instructions on each decal carefully. In the eventany decal becomes illegible or comes off, contact your Polaris dealerfor a replacement. Any safety decal needing replac...

17 SAFETY Safety Decals and Locations Never operate this ATV on HILLS steeper than 25 degrees To prevent flipover on hilly terrain, when going up or down,use throttle and brakes gradually. 25 ° REVERSE operation can be dangerous even at low speeds. Steering becomes difficult. To prevent flipover, av...

19 SAFETY Safety Decals and Locations 4 5 IMPROPER TIRE PRESSURE OR OVERLOADING can cause lossof 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. Redu...

20 SAFETY Safety Decals and Locations 7 8 (Under Seat) 7 8 M ov ing par t s haz ar d under belt - c lut c h guar d. Topr ev ent ser ious injur y, do not oper at e vehic le wit hguar d rem ov ed. Do not modify engine or clutch. Doing so can cause partfailure, possible imbalance, and excessive engine ...

22 SAFETY Safe Riding Gear Always wear clothing suited to the type of riding you are doing. ATVriding requires special protective clothing which will make you feelmore comfortable and reduce chances of injury. 1. Helmet Your helmet is the most importantpiece of protective gear for saferiding. A helm...

23 SAFETY Operator Safety POTENTIAL HAZARD Operating this ATV without proper instruction. WHAT CAN HAPPEN The risk of an accident is greatly increased if the operatordoes not know how to operate the ATV properly in differentsituations and on different types of terrain. HOW TO AVOID THE HAZARD Beginn...

44 CONTROLS AND FEATURES Controls Engine Electrical Switches 1. Override Switch (Reverse Speed Limiter) - This vehicle is equippedwith a reverse speed limitersystem. To obtain additional powerwhile backing up, depress theoverride button. NOTE: The override switch also allowsactivation of AWD (All Wh...

45 CONTROLS AND FEATURES Controls Engine Throttle and Choke Throttle Lever Engine speed and vehiclemovement are controlled bypressing the throttle lever.The throttle lever (1) is springloaded and engine speedreturns to idle when the leveris released.This vehicle is equipped witha Polaris Electronic ...

46 CONTROLS AND FEATURES Controls Brakes The front and rear brakes are applied by squeezing the left side brakelever toward the handlebar. The front and rear brakes are hydraulicallyactivated disc type brakes which are activated by one lever only.Always test brake lever travel and reservoir fluid le...

47 CONTROLS AND FEATURES Controls Front and Rear Brakes The brake fluid in the mastercylinder, which is located on theleft handlebar, should be checkedbefore each ride. The fluid levelcan be seen through an indicatorwindow (1) on the top of themaster cylinder. This “eye” willappear dark when the flu...

48 CONTROLS AND FEATURES Controls Parking Brake Setting the Parking Brake 1. Put the vehicle gear selector into park. 2. Squeeze the left hand brake lever two or three times andhold it. 3. Push the park brake lock (2) into the notches on the mastercylinder body. Release thebrake lever. 4. To release...

49 CONTROLS AND FEATURES Controls Foot Brake Your Polaris ATV has a foot brake (1) provided as a safety feature. Itis located on the inside of the right floor board and is operated by theright foot. It is intended as a backup to the main brake system,especially if the main system becomes inoperative...

50 CONTROLS AND FEATURES Controls Fuel System The fuel tank filler cap (1)is located directly behindthe handlebar. Refer tovehicle specifications onpage 7 for tank capacity.Use either leaded orunleaded gasoline with aminimum pump octanenumber of 87 (R+ M/2)octane.The fuel valve is located onthe left...

51 CONTROLS AND FEATURES Controls Fuel Safety Gasoline is highly flammable and explosive under certainconditions. Always exercise extreme caution whenever handling gasoline. Always refuel with the engine stopped and outdoors or in a well ventilated area. Do not smoke or allow open flames or sparks i...

52 CONTROLS AND FEATURES Controls Automatic Transmission Gear Selector The transmission gear selector is locatedon0 the right side of the vehicle directlyabove and forward of the engine and hasfive positions: high, low, neutral; reverse,and park. To shift into “High” or “Park”, youmust first depress...

53 CONTROLS AND FEATURES Important Safeguards Always back slowly avoiding excessive speed and do not use the reverse speed override switch system unless additional power isrequired for vehicle movement. Avoid turning at sharp angles in reverse. Avoid backing on steep inclines. Light Switches and Ind...

54 CONTROLS AND FEATURES Features Exclusive AWD System (All Wheel Drive) Polaris 4 wheel drive ATVs areequipped with a unique, Polarisexclusive, All Wheel Drive(AWD) system which isactivated by a switch (1) on theright handlebar. When theswitch is “off” the ATV is in 2wheel drive at all times. Whent...

55 CONTROLS AND FEATURES Features Exclusive AWD System (All Wheel Drive) Engage the All Wheel Drive switch before getting into conditionswhere front wheel drive may be needed. If the rear wheels arespinning, release the throttle before turning the All Wheel Drive switchon. NOTE: If the instrument cl...

56 CONTROLS AND FEATURES Features Instrument Cluster Your Sportsman 700 is equipped with an instrument cluster whichsenses vehicle speed from the right hand front wheel. The instrumentcluster measures distance in miles as well as hours of operation. It alsoincludes a reverse speed limiter function t...

57 CONTROLS AND FEATURES Features Rider Information Center The rider information center is located in the lower portion of theinstrument cluster.1 Gear Indicator -As the shift leveris moved, thiswill indicate thegear the machineis in:H = High RangeL = Low RangeN = NeutralR = ReverseP = Park E or bla...

58 CONTROLS AND FEATURES Features Rider Information Center The rider information center has 4 standard modes:Mode 1 - OdometerMode 2 - TripmeterMode 3 - Total Service HoursMode 4 - Programmable service intervalThe reverse override button which is found on the LH handlebar is alsothe “mode button”. N...

59 CONTROLS AND FEATURES Features Rider Information Center Mode 4 - Programmable Service Interval The purpose of the programmable service interval is to provide theconsumer and their dealer with a convenient way to schedule routinemaintenance. When your vehicle leaves the factory, this feature istur...

60 CONTROLS AND FEATURES Features Rider Information Center Diagnostic Mode To enter the diagnostics mode:1. Turn the key switch off and wait 20 seconds.2. Set the park brake and shift the transmission to neutral.3. Hold the mode/reverse override button as you turn the key switch on. The initial scre...

61 CONTROLS AND FEATURES Features Rider Information Center The second screenprovides a fulldiagnosticindication of theentire oil pressureelectrical circuit.Along with theletters PrSSr, therewill be a box onthe LH side. If thebox is high, thepressure is normal.If the box is low,the pressure is low.Sc...

62 OPERATION Pre Ride Inspection Use the following checklist to verify your machine is in properworking order each time you ride. Item/Inspection Procedure 1. Tires - check condition and pressures2. Fuel and oil tanks - fill both tanks to their proper levels3. All brakes - check operation, adjustmen...

63 OPERATION Break-In Period The break in period for your new Polaris ATV is defined as the first tenhours of operation, or the time it takes to use the first two tanks full ofgasoline. No single action on your part is as important as a properbreak in period. Careful treatment of a new engine will r...

64 OPERATION Starting the Engine Procedure for Starting a Cold Engine 1. Place the transmission in neutral or park and reset theparking brake. 2. Turn the fuel tank valve to ON.3. Sit on the vehicle.4. Pull the choke out all the way.5. Turn the engine stop switch to RUN. 6. Turn the ignition key pas...

65 OPERATION Starting the Engine After the Engine Starts 1. If the engine slows or stops, use of the choke at half way in will allow proper engine warm up. 2. Vary the engine RPM slightly with the throttle to aid in warm up until the engine idles smoothly. Then push the choke all the wayin. Cold Wea...

66 OPERATION Carrying Loads Your ATV has been designed to carry a certain amount of load.CARGO WEIGHT should be evenly distributed (1/3 on the front and2/3 on the rear) and mounted as low as possible. When operating overrough or hilly terrain, reduce speed and cargo to maintain stabledriving conditi...

67 OPERATION Carrying Loads Important Safeguards To reduce risk of injury or machine damage when carrying loads, readand follow the warnings listed below: REDUCE SPEED AND ALLOW GREATER DISTANCE FOR BRAKING WHEN CARRYING CARGO. CARGO WEIGHT DISTRIBUTION should be 1/3 on the front rack and 2/3 on the...

69 NOISE EMISSION CONTROL SYSTEM REGULATION TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED!U.S. Federal law prohibits the following acts or the causing thereof:(1) The removal or rendering inoperative by any person other than forpurposes of maintenance, repair, or replacement of any device orelement...

70 RIDING Pre Ride Inspection Use the following checklist to verify your machine is in properworking order each time you ride. Item/Inspection Procedure 1. Tires - check condition and pressures2. Fuel and oil tanks - fill both tanks to their proper levels3. All brakes - check operation, adjustment a...

71 RIDING Safe Riding Tips Riding Position 1. Sit upright with both feet on the footrests and both hands on the handlebars. 2. After starting the engine and allowing it to warm up, shift the transmission into gear. 3. Check your surroundings and determine your path of travel.4. Release the parking b...

72 RIDING Safe Riding Tips Making Turns Practice making turns at slow speeds. To turn, steer in the direction of the turn leaning your upper body to theinside of the turn while supporting your weight on the outer footrest.The same leaning technique should be used for turning in reverse. Avoid turnin...

73 RIDING Safe Riding Tips Riding on Slippery Surfaces Whenever riding on slippery surfaces such as wet trails orloose gravel, or during cold freezing weather, special atten-tion must be paid to prevent vehicle turnover. Always: 1. Slow down when entering slippery areas.2. Maintain a high level of a...

74 RIDING Safe Riding Tips Traveling Uphill Whenever traveling uphill always travel straight uphill and: 1. Avoid steep hills (25 maximum). 2. Keep both feet on the footrests.3. Transfer your weight forward.4. Proceed at a steady rate of speed and throttle opening.5. Remain alert and be prepared to ...

75 RIDING Safe Riding Tips Sidehilling Sidehilling your ATV is one of the most dangerous types ofriding and should be avoided if possible. In the event you doenter into a situation where sidehilling is necessary, always: 1. Slow down. 2. Lean into the hill transferring your upper body weight toward ...

76 RIDING Safe Riding Tips Traveling Downhill Whenever descending a hill, always: 1. Drive 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 the foot brake and its use in the event loss ofnormal...

77 RIDING Safe Riding Tips Turning Around on a Hill If the ATV stalls while climbing a hill, never back it down thehill! One maneuver which can be used when it is necessaryto turn around while climbing a hill is the K-turn. 1. Stop and lock the parking brake while maintaining body weight uphill. 2. ...

78 RIDING Safe Riding Tips Crossing Streams Your Polaris ATV can operate through water up to maximumrecommended depths reaching the footrests. Before fordingstreams always: 1. Determine water depths and current.2. Choose a crossing where both banks have gradual inclines.3. Proceed slowly, avoiding r...

79 RIDING Safe Riding Tips Trail Obstacles Keep Alert! Look ahead and learn to read the trail as you ride. Stay on the rightside of the trail, if possible, and be constantly alert for hazards such aslogs, rocks and low hanging branches. Not all obstacles are visible. Travel with caution on trails.se...

80 RIDING Safe Riding Tips Backing Up 1. Avoid backing up on steep inclines.2. Always 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.6. Never activate override button while throttle i...

81 RIDING Safe Riding Tips Parking on an Incline Whenever the Vehicle is Parked 1. Turn the engine off.2. Place the transmission in park.3. Set the parking brake.4. Avoid parking on an incline. If it is necessary to park on an incline, always block the rear wheels on the down hill side asshown above...

82 MAINTENANCE AND LUBRICATION Periodic Maintenance Schedule Careful periodic maintenance will help keep your vehicle in the safest,most reliable condition. Inspection, adjustment and lubricationintervals of important components are explained in the following charton the following pages.Maintenance ...

84 MAINTENANCE AND LUBRICATION Periodic Maintenance Schedule More often under severe use, such as dirty or wet conditions to purge water or dirt contamination from grease fittings and othercritical components. Emission Control System Service (California - 4-Cycle) NOTE: Some 4-Cycle models may have ...

88 MAINTENANCE AND LUBRICATION Lubrication Recommendations Item Lube Rec Method Frequency* (1)Engine Oil PolarisPremium4 Synthet-ic 0W40 Add to proper level on dip-stick. See page 96. Check leveldaily. (2) BrakeFluid DOT 3Only Maintain level between filllines. See page 47. As required;change everytw...

89 MAINTENANCE AND LUBRICATION Lubrication Recommendations (6) Front Prop Shaft(U-Joints) (4) Front Gear Case (3) Transmission(plug) (7) Propshaft Yoke Fill plug Fill plug (5) Rear Gear Case

90 MAINTENANCE AND LUBRICATION Lubrication Recommendations (8) FrontDrive Axle (UJoint) (AWDModels) Grease + Locate grease fitting andgrease with grease gun. Every 3months or50 hours (9) Ball Joint Grease** Locate fitting on back side ofstruts and grease with greasegun. Every 3months or50 hours (10)...

91 MAINTENANCE AND LUBRICATION Lubrication Recommendations (8) Axle CardanFront Drive (11) SteeringPostBushing Upper (12) Upper ControlArm (14) Rear WheelHub BearingCarrier (15) Rear Anti-Roll Bar (13) Lower Control Arm (13) Lower Con-trol Arm (10) Front A Arm Pivot Shaft

92 MAINTENANCE AND LUBRICATION Periodic Maintenance Record Use the following chart to record periodic maintenance work: Maintenance Interval Performed Servicing Date Servicing Dealer or Person Remarks First 5 Hrs. 25 Hrs. 50 Hrs. 75 Hrs. 100 Hrs.

93 MAINTENANCE AND LUBRICATION Engine Cooling System Coolant Level The recovery bottle(1), located onthe left side of the machine, must bemaintained between the minimumand maximum levels indicated onthe recovery bottle.The engine coolant level iscontrolled or maintained by therecovery system. The re...

94 MAINTENANCE AND LUBRICATION Engine Cooling System Radiator Coolant Level Inspection NOTE: This procedure is only required if the coolingsystem has been drained formaintenance and/or repair.However, if the recovery bottlehas run dry, the level in theradiator should be inspectedand coolant added if...

95 MAINTENANCE AND LUBRICATION Engine Cooling System NOTE: Use of a non-standard pressure cap will not allow the recovery system to function properly. If the cap should needreplacement contact your dealer for the correct replacement part.To insure that the coolant maintains its ability to protect th...

96 MAINTENANCE AND LUBRICATION Lubrication 4-Cycle Premium 4 Synthetic Lubricant Polaris Premium 4 All Season Synthetic engine oil has been speciallyformulated for use in Polaris 4-cycle engines. It is a fully synthetic,high performance, multi-viscosity oil designed to provide the ultimatein lubrica...

97 MAINTENANCE AND LUBRICATION Lubrication Oil and Filter Change 1. Place vehicle on a level surface.2. Run engine two to three minutes until warm. Stop engine.3. Clean area around drain plug.4. Place a drain pan beneath engine crankcase and remove drain plug. CAUTION: Oil may be hot. Do not allow h...

98 MAINTENANCE AND LUBRICATION Lubrication Transmission Lubrication The transmission fill plug is located on the right side of the machinebehind the propshaft shield or footwell.The transmission lubricant level should be checked every six months or1000 miles (1600 km), whichever comes first. Transmi...

99 MAINTENANCE AND LUBRICATION Lubrication Front Gearcase Lubrication The front gearcase fill plug islocated as shown.The front gearcase lubricant levelshould be checked every six monthsor 1000 miles (1600 km), whichevercomes first. Front gearcase oilshould be changed annually.With the ATV on a leve...

100 MAINTENANCE AND LUBRICATION Lubrication Rear Gearcase Lubrication With the ATV on a levelsurface, remove the fill plug andvisually inspect the lubricantlevel through the fill hole (1).The lubricant level should bemaintained 1 5/8 in. from thetop of the fill plug hole. UseGL5 80-90 weight gear lu...

101 MAINTENANCE AND LUBRICATION Lubrication Oil System The oil dipstick and fill tube are located on the left side of the vehicleTo check the oil:1. Set machine on a level surface. 2. Start the engine and let it idle for 20-30seconds. 3. Stop the engine and lift the lever lock (A) onthe dipstick. Re...

102 MAINTENANCE AND LUBRICATION Filter Systems Cleaning the Main Filter NOTE: It is advisable to replace the filter when it is dirty. However, in an emergency it is permissible to clean the main filter if you observethe following practices.1. Never immerse the filter in water since dirt can be trans...

104 MAINTENANCE AND LUBRICATION Adjustments Steering Inspection The steering assembly of the machine should be checked periodicallyfor loose nuts and bolts. If loose nuts and bolts are found, have yourdealer tighten them before riding your vehicle. Camber and Caster The camber and caster are non-adj...

105 MAINTENANCE AND LUBRICATION Adjustments Toe Alignment (cont.) 2. Place stands in front of the machine, perpendicular to the rear tires.3. Tie an elastic string around the stands, making sure string just touches side surface of the rear tires on each side of machine andgoes around the stands in f...

106 MAINTENANCE AND LUBRICATION Adjustments Rear Spring Adjustment The rear shock absorber spring is adjusted by rotating the adjuster inthe direction required to increase or decrease spring tension. NOTE: Accessory springs are available through your Polaris dealer. Rear SpringAdjustmentCam

107 MAINTENANCE AND LUBRICATION Adjustments Handlebar Adjustment Your ATV has handlebars whichcan be adjusted for yourpersonal fit.1. To locate handlebar bolts, it will be necessary toremove the upper headlightpod. 2. Loosen the four bolts.3. Adjust handlebar to desired height. Be sure handlebars do...

108 MAINTENANCE AND LUBRICATION Adjustments Front Brake The front brakes are hydraulic disc brakes which are activated by thebrake lever being moved toward the handlebar. These brakes areself-adjusting and require no adjustment.The following checks are recommended to keep the brake system ingood ope...

109 MAINTENANCE AND LUBRICATION Adjustments Rear Brake The rear brake is a hydraulic disc type brake which is activated by thesame lever which activates the front brake system. The rear brakesystem is self adjusting and requires no maintenance other thanperiodic checks of the pads for wear. Pads sho...

110 MAINTENANCE AND LUBRICATION Adjustments Carburetor/Engine Idle RPM Adjustment If the engine idle speed is notsatisfactory, and all otherconditions are favorable, thecarburetor can be adjusted asfollows:1. Warm up the engine by running the vehicleapproximately fiveminutes. 2. Place the transmissi...

111 MAINTENANCE AND LUBRICATION Adjustments Important Safeguards Maintain proper tire pressure according to the tire pressure decal.Improper tire inflation may affect ATV maneuverability.Do not use improper tires. The use of non-standard size or type tiresmay affect ATV handling.Make certain the whe...

112 MAINTENANCE AND LUBRICATION Adjustments Wheel Installation 1. With the transmission in park and the parkingbrake locked, place thewheel in the correctposition on the wheelhub. Be sure the valvestem is toward the outsideand rotation arrows on thetire point toward forwardrotation. 2. Attach the wh...

113 MAINTENANCE AND LUBRICATION Adjustments Tire Inspection When replacing a tire alwaysuse original equipment sizeand type. Tire Tread Depth Always replace tires whentread depth is worn to 1/8 ″ (.3 cm) (1) or less. 1

114 MAINTENANCE AND LUBRICATION Adjustments Carburetor Adjustments If the vehicle is to be operated at various altitudes and temperatures,certain adjustments can be made to improve its operation anddriveability. Above 6000 feet (1800 m) the engine air/fuel mixturebecomes overly rich. An engine loses...

115 MAINTENANCE AND LUBRICATION Lights - Adjustment - Replacement Headlight Lamp Replacement Keep your headlights and taillights clean. Poor lighting while ridingcan result in an accident causing severe injury or death. Do not service while headlight is hot. Serious burns may result. Do not touch a ...

116 MAINTENANCE AND LUBRICATION Lights - Adjustment - Replacement Headlight Lamp Replacement 1. Remove the three screws securing 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 lightl...

117 MAINTENANCE AND LUBRICATION Lights - Adjustment - Replacement High Beam Headlight Adjustment The headlight beam can be adjusted to any position desired by turningthe adjusting knob located on the bottom right side of the headlightpod.1. Place the vehicle on a level surface with the headlight app...

118 MAINTENANCE AND LUBRICATION Lights - Adjustment - Replacement Headlight Housing Replacement 1. Lift the pod lightly while depressing the tabs.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. Remove the three scr...

119 MAINTENANCE AND LUBRICATION Lights - Adjustment - Replacement Taillight/Brakelight Lamp Replacement If the taillight/brakelight does notwork the lamp may need to bereplaced.1. Remove the taillight lens cover mounting screws. Remove thelense cover and gasket and setaside for reassembly. 2. Remove...

120 MAINTENANCE AND LUBRICATION Spark Plugs Refer to page 7 for the correct spark plug for your machine.The spark plug and its condition is indicative of engine operation. Thespark plug firing end condition should be read after the engine iswarmed up and the vehicle is driven at higher speeds. Immed...

121 MAINTENANCE AND LUBRICATION Water Immersion If it is impossible to take it to a dealer before starting, follow the stepsoutlined below. Move the ATV to dry land or at the very least, to water below the footrests. Turn the fuel valve off. Remove the spark plugs. Loosen the carburetor drain screw ...

122 MAINTENANCE AND LUBRICATION Spark Arrestor Spark Arrestor The exhaust pipe must be periodically purged of accumulated carbon asfollows:1. Remove the clean out plug (1) located on the bottom of the muffler.2. Place the transmission in neutral and start the engine. Purge accumulated carbon from th...

123 MAINTENANCE AND LUBRICATION Spark Arrestor (cont.) 4. If particles are still suspected to be in themuffler, back themachine onto anincline so the rear ofthe machine is one foothigher than the front.Set the parking brakeand block the wheels.Make sure the machineis in neutral and repeat steps 2 an...

124 MAINTENANCE AND LUBRICATION PVT System Low Range Use May Reduce PVT Operating Temperatures The basic operation of the Polaris PVT system is dependent on enginespeed and vehicle torque requirements. As engine speed increases, theforce exerted on the movable drive sheave by the flyweights alsoincr...

125 MAINTENANCE AND LUBRICATION PVT System On Polaris ATVs, the approximate gear ratio difference between highand low range is 1:2.25. This difference in gearing affects the operationof the PVT, especially at speeds less than 7 MPH, due to the system’sdependence on engine speed.For example, when ope...

126 MAINTENANCE AND LUBRICATION PVT System When To Use Low Range vs. High Range The following lists provide a guideline for when to use low rangerather than high. Low Range: Basic operation at speeds less than 7 MPH Heavy pulling Riding through rough terrain (swamps, mountains, etc.) at low ground s...

127 MAINTENANCE AND LUBRICATION Battery Replenishing the Battery Fluid A poorly maintained battery willdeteriorate rapidly. Check thebattery fluid level often. The fluidlevel should be kept between theupper and lower level marks.To refill use only distilled water.Tap water contains minerals whichare...

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

129 MAINTENANCE AND LUBRICATION Battery 1. Set the battery in its holder.2. Install the battery vent tube. It must be free from obstructions and securely installed. If not, battery gases could accumulate and cause anexplosion. The tube should be routed away from the frame and bodyto prevent corrosio...

130 MAINTENANCE AND LUBRICATION Side Panel Removal Side panel removal may be difficult until the locking tabs and receivershave been snapped and unsnapped a few times.1. Remove seat. Grasp rear of side panel nearrear cab. With a quickand firm motion, pullthe panel forward andoutward to disengagethe ...

131 MAINTENANCE AND LUBRICATION Cleaning and Storage Cleaning the ATV Keeping your ATV clean will not only improve its appearance but itcan also extend the life of various components. With a fewprecautions, your ATV can be cleaned much like an automobile. Washing the ATV If a high pressure type car ...

132 MAINTENANCE AND LUBRICATION Cleaning and Storage Storage Tips Cleaning - Outside...Make necessary repairs and then clean the ATV thoroughly with a mild soap and warm water solution to remove all dirtand grime. Don’t use harsh detergents or high pressure washers. Somedetergents deteriorate rubber...

133 MAINTENANCE AND LUBRICATION Cleaning and Storage * Fog The Engine - Remove the spark plug and add 2-3 tablespoons of Premium 4 Synthetic 0W40 engine oil. To access the plug hole use asection of clear 1/4 ″ hose and a small plastic squeeze bottle filled with the pre-measured amount of oil. Instal...

134 MAINTENANCE AND LUBRICATION Transporting Whenever the ATV is to be transported the following measures shouldbe taken.1. Turn off the engine and remove the key. It may be lost if not removed. 2. Turn the fuel valve to off.3. Be certain the fuel cap, oil cap, and seat are installed correctly.4. Al...

135 TROUBLESHOOTING Clutch Drive Belt & Cover Related Issues: Diagnosis Possible Causes Solutions/What to do Loading the ATV into a pick-up or tall trailer when in highrange. Shift transmission to low range duringloading of the ATV to prevent belt burn-ing. Starting out going up asteep incline. ...

137 TROUBLESHOOTING Procedures The following information is provided to help you identify probablecauses for questions you may have about the operation of your ATV.See your Polaris dealer with any additional questions you may have. ENGINE TURNS OVER BUT FAILS TO START No Fuel Water in Fuel Spark Plu...

141 WARRANTY LIMITED WARRANTY Polaris Industries Inc., 2100 Highway 55, Medina, MN 55340, gives aSIX MONTH LIMITED WARRANTY on all components of thePolaris All Terrain Vehicle (ATV) against defects in material orworkmanship. Polaris also gives a one year limited warranty on thefinal drive chain for ...

142 WARRANTY WARRANTY COVERAGE AND EXCLUSIONS: LIMITATIONS OF WARRANTIES AND REMEDIES The Polaris limited warranty excludes any failures that are not causedby a defect in material or workmanship. This warranty does not coveraccidental damage, normal wear and tear, abuse or improper handling.This war...

143 WARRANTY ALL IMPLIED WARRANTIES (INCLUDING BUT NOT LIMITEDTO THE IMPLIED WARRANTIES OF MERCHANTABILITY ANDFITNESS FOR A PARTICULAR PURPOSE) ARE LIMITED INDURATION TO THE ABOVE SIX MONTH WARRANTY PERIOD.POLARIS FURTHER DISCLAIMS ALL EXPRESS WARRANTIESNOT STATED IN THIS WARRANTY. Some states do no...

144 INDEX Accessories 114 . . . . . . . . . . . . . . . . . . Adjustments 104-114 . . . . . . . . . . . . . . Age Restrictions 3 . . . . . . . . . . . . . . . . Air Filter 102 . . . . . . . . . . . . . . . . . . . . All Wheel Drive 54-55 . . . . . . . . . . . . . Anti–Freeze 133 . . . . . . . . . . ...

5 TABLE OF CONTENTS Maintenance and Lubrication 82 . . . . . . . . . . . . . . . Periodic Maintenance Schedule 82 . . . . . . . . . . . . . . . . . . Lubrication Recommendations 88 . . . . . . . . . . . . . . . . . . . Maintenance Record 92 . . . . . . . . . . . . . . . . . . . . . . . . . . . Cooli...

6 VEHICLE IDENTIFICATION NUMBERS The frame vehicle identification number (VIN) (1) and engine serialnumber (2) are important for model identification when registeringyour vehicle, when obtaining insurance, and when orderingreplacement parts. If your vehicle is stolen, these numbers are essentialto i...

7 VEHICLE SPECIFICATIONS SPORTSMAN 700 Gross Vehicle Weight 1240 lbs. Fuel Capacity 4.75 U.S. Gallons Towing Capacity 1500 lbs Hitch Tongue Capacity 150 lbs Overall Length 85” Overall Width 46” Overall Height 47” Wheelbase 50.75 Ground Clearance 11” Dry Weight 740 lbs Minimum Turning Radius 71.5” En...

8 VEHICLE 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 F...

9 SAFETY Understanding Warnings The following two pages identify signal words and symbols that appearin this manual. Your safety is involved when these words and symbolsare used. Become familiar with their meanings before reading themanual. The safety alert symbol , on your vehicle or in this manual...

10 SAFETY Key Safety Issues Protect Your Sport Know all local, state/province riding laws;Respect your vehicle;Respect the environment; andYou will gain the respect of others.We also advise you to strictly follow the recommended maintenanceprogram as outlined. This preventive maintenance program is ...

11 SAFETY Key Safety Issues SERIOUS INJURY OR DEATH can result if you do notfollow these instructions: Read this manual and all labels carefully and follow the operating procedures described. Never operate an ATV without proper instruction. Take a training course. Beginners should receive training f...

13 SAFETY Key Safety Issues Always be sure there are no obstacles or people behind you when you operate in reverse. When it is safe to proceed in reverse, goslowly. Avoid turning at sharp angles in reverse. Always use the size and type tires specified in this manual. Always maintain proper tire pres...

14 SAFETY Safety Decals and Locations NOTE: Warning decals have been placed on the vehicle for your protection.Read and follow the instructions on each decal carefully. In the eventany decal becomes illegible or comes off, contact your Polaris dealerfor a replacement. Any safety decal needing replac...

17 SAFETY Safety Decals and Locations Never operate this ATV on HILLS steeper than 25 degrees To prevent flipover on hilly terrain, when going up or down,use throttle and brakes gradually. 25 ° REVERSE operation can be dangerous even at low speeds. Steering becomes difficult. To prevent flipover, av...

19 SAFETY Safety Decals and Locations 4 5 IMPROPER TIRE PRESSURE OR OVERLOADING can cause lossof 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. Redu...

20 SAFETY Safety Decals and Locations 7 8 (Under Seat) 7 8 M ov ing par t s haz ar d under belt - c lut c h guar d. Topr ev ent ser ious injur y, do not oper at e vehic le wit hguar d rem ov ed. Do not modify engine or clutch. Doing so can cause partfailure, possible imbalance, and excessive engine ...

22 SAFETY Safe Riding Gear Always wear clothing suited to the type of riding you are doing. ATVriding requires special protective clothing which will make you feelmore comfortable and reduce chances of injury. 1. Helmet Your helmet is the most importantpiece of protective gear for saferiding. A helm...

23 SAFETY Operator Safety POTENTIAL HAZARD Operating this ATV without proper instruction. WHAT CAN HAPPEN The risk of an accident is greatly increased if the operatordoes not know how to operate the ATV properly in differentsituations and on different types of terrain. HOW TO AVOID THE HAZARD Beginn...

44 CONTROLS AND FEATURES Controls Engine Electrical Switches 1. Override Switch (Reverse Speed Limiter) - This vehicle is equippedwith a reverse speed limitersystem. To obtain additional powerwhile backing up, depress theoverride button. NOTE: The override switch also allowsactivation of AWD (All Wh...

45 CONTROLS AND FEATURES Controls Engine Throttle and Choke Throttle Lever Engine speed and vehiclemovement are controlled bypressing the throttle lever.The throttle lever (1) is springloaded and engine speedreturns to idle when the leveris released.This vehicle is equipped witha Polaris Electronic ...

46 CONTROLS AND FEATURES Controls Brakes The front and rear brakes are applied by squeezing the left side brakelever toward the handlebar. The front and rear brakes are hydraulicallyactivated disc type brakes which are activated by one lever only.Always test brake lever travel and reservoir fluid le...

47 CONTROLS AND FEATURES Controls Front and Rear Brakes The brake fluid in the mastercylinder, which is located on theleft handlebar, should be checkedbefore each ride. The fluid levelcan be seen through an indicatorwindow (1) on the top of themaster cylinder. This “eye” willappear dark when the flu...

48 CONTROLS AND FEATURES Controls Parking Brake Setting the Parking Brake 1. Put the vehicle gear selector into park. 2. Squeeze the left hand brake lever two or three times andhold it. 3. Push the park brake lock (2) into the notches on the mastercylinder body. Release thebrake lever. 4. To release...

49 CONTROLS AND FEATURES Controls Foot Brake Your Polaris ATV has a foot brake (1) provided as a safety feature. Itis located on the inside of the right floor board and is operated by theright foot. It is intended as a backup to the main brake system,especially if the main system becomes inoperative...

50 CONTROLS AND FEATURES Controls Fuel System The fuel tank filler cap (1)is located directly behindthe handlebar. Refer tovehicle specifications onpage 7 for tank capacity.Use either leaded orunleaded gasoline with aminimum pump octanenumber of 87 (R+ M/2)octane.The fuel valve is located onthe left...

51 CONTROLS AND FEATURES Controls Fuel Safety Gasoline is highly flammable and explosive under certainconditions. Always exercise extreme caution whenever handling gasoline. Always refuel with the engine stopped and outdoors or in a well ventilated area. Do not smoke or allow open flames or sparks i...

52 CONTROLS AND FEATURES Controls Automatic Transmission Gear Selector The transmission gear selector is locatedon0 the right side of the vehicle directlyabove and forward of the engine and hasfive positions: high, low, neutral; reverse,and park. To shift into “High” or “Park”, youmust first depress...

53 CONTROLS AND FEATURES Important Safeguards Always back slowly avoiding excessive speed and do not use the reverse speed override switch system unless additional power isrequired for vehicle movement. Avoid turning at sharp angles in reverse. Avoid backing on steep inclines. Light Switches and Ind...

54 CONTROLS AND FEATURES Features Exclusive AWD System (All Wheel Drive) Polaris 4 wheel drive ATVs areequipped with a unique, Polarisexclusive, All Wheel Drive(AWD) system which isactivated by a switch (1) on theright handlebar. When theswitch is “off” the ATV is in 2wheel drive at all times. Whent...

55 CONTROLS AND FEATURES Features Exclusive AWD System (All Wheel Drive) Engage the All Wheel Drive switch before getting into conditionswhere front wheel drive may be needed. If the rear wheels arespinning, release the throttle before turning the All Wheel Drive switchon. NOTE: If the instrument cl...

56 CONTROLS AND FEATURES Features Instrument Cluster Your Sportsman 700 is equipped with an instrument cluster whichsenses vehicle speed from the right hand front wheel. The instrumentcluster measures distance in miles as well as hours of operation. It alsoincludes a reverse speed limiter function t...

57 CONTROLS AND FEATURES Features Rider Information Center The rider information center is located in the lower portion of theinstrument cluster.1 Gear Indicator -As the shift leveris moved, thiswill indicate thegear the machineis in:H = High RangeL = Low RangeN = NeutralR = ReverseP = Park E or bla...

58 CONTROLS AND FEATURES Features Rider Information Center The rider information center has 4 standard modes:Mode 1 - OdometerMode 2 - TripmeterMode 3 - Total Service HoursMode 4 - Programmable service intervalThe reverse override button which is found on the LH handlebar is alsothe “mode button”. N...

59 CONTROLS AND FEATURES Features Rider Information Center Mode 4 - Programmable Service Interval The purpose of the programmable service interval is to provide theconsumer and their dealer with a convenient way to schedule routinemaintenance. When your vehicle leaves the factory, this feature istur...

60 CONTROLS AND FEATURES Features Rider Information Center Diagnostic Mode To enter the diagnostics mode:1. Turn the key switch off and wait 20 seconds.2. Set the park brake and shift the transmission to neutral.3. Hold the mode/reverse override button as you turn the key switch on. The initial scre...

61 CONTROLS AND FEATURES Features Rider Information Center The second screenprovides a fulldiagnosticindication of theentire oil pressureelectrical circuit.Along with theletters PrSSr, therewill be a box onthe LH side. If thebox is high, thepressure is normal.If the box is low,the pressure is low.Sc...

62 OPERATION Pre Ride Inspection Use the following checklist to verify your machine is in properworking order each time you ride. Item/Inspection Procedure 1. Tires - check condition and pressures2. Fuel and oil tanks - fill both tanks to their proper levels3. All brakes - check operation, adjustmen...

63 OPERATION Break-In Period The break in period for your new Polaris ATV is defined as the first tenhours of operation, or the time it takes to use the first two tanks full ofgasoline. No single action on your part is as important as a properbreak in period. Careful treatment of a new engine will r...

64 OPERATION Starting the Engine Procedure for Starting a Cold Engine 1. Place the transmission in neutral or park and reset theparking brake. 2. Turn the fuel tank valve to ON.3. Sit on the vehicle.4. Pull the choke out all the way.5. Turn the engine stop switch to RUN. 6. Turn the ignition key pas...

65 OPERATION Starting the Engine After the Engine Starts 1. If the engine slows or stops, use of the choke at half way in will allow proper engine warm up. 2. Vary the engine RPM slightly with the throttle to aid in warm up until the engine idles smoothly. Then push the choke all the wayin. Cold Wea...

66 OPERATION Carrying Loads Your ATV has been designed to carry a certain amount of load.CARGO WEIGHT should be evenly distributed (1/3 on the front and2/3 on the rear) and mounted as low as possible. When operating overrough or hilly terrain, reduce speed and cargo to maintain stabledriving conditi...

67 OPERATION Carrying Loads Important Safeguards To reduce risk of injury or machine damage when carrying loads, readand follow the warnings listed below: REDUCE SPEED AND ALLOW GREATER DISTANCE FOR BRAKING WHEN CARRYING CARGO. CARGO WEIGHT DISTRIBUTION should be 1/3 on the front rack and 2/3 on the...

69 NOISE EMISSION CONTROL SYSTEM REGULATION TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED!U.S. Federal law prohibits the following acts or the causing thereof:(1) The removal or rendering inoperative by any person other than forpurposes of maintenance, repair, or replacement of any device orelement...

70 RIDING Pre Ride Inspection Use the following checklist to verify your machine is in properworking order each time you ride. Item/Inspection Procedure 1. Tires - check condition and pressures2. Fuel and oil tanks - fill both tanks to their proper levels3. All brakes - check operation, adjustment a...

71 RIDING Safe Riding Tips Riding Position 1. Sit upright with both feet on the footrests and both hands on the handlebars. 2. After starting the engine and allowing it to warm up, shift the transmission into gear. 3. Check your surroundings and determine your path of travel.4. Release the parking b...

72 RIDING Safe Riding Tips Making Turns Practice making turns at slow speeds. To turn, steer in the direction of the turn leaning your upper body to theinside of the turn while supporting your weight on the outer footrest.The same leaning technique should be used for turning in reverse. Avoid turnin...

73 RIDING Safe Riding Tips Riding on Slippery Surfaces Whenever riding on slippery surfaces such as wet trails orloose gravel, or during cold freezing weather, special atten-tion must be paid to prevent vehicle turnover. Always: 1. Slow down when entering slippery areas.2. Maintain a high level of a...

74 RIDING Safe Riding Tips Traveling Uphill Whenever traveling uphill always travel straight uphill and: 1. Avoid steep hills (25 maximum). 2. Keep both feet on the footrests.3. Transfer your weight forward.4. Proceed at a steady rate of speed and throttle opening.5. Remain alert and be prepared to ...

75 RIDING Safe Riding Tips Sidehilling Sidehilling your ATV is one of the most dangerous types ofriding and should be avoided if possible. In the event you doenter into a situation where sidehilling is necessary, always: 1. Slow down. 2. Lean into the hill transferring your upper body weight toward ...

76 RIDING Safe Riding Tips Traveling Downhill Whenever descending a hill, always: 1. Drive 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 the foot brake and its use in the event loss ofnormal...

77 RIDING Safe Riding Tips Turning Around on a Hill If the ATV stalls while climbing a hill, never back it down thehill! One maneuver which can be used when it is necessaryto turn around while climbing a hill is the K-turn. 1. Stop and lock the parking brake while maintaining body weight uphill. 2. ...

78 RIDING Safe Riding Tips Crossing Streams Your Polaris ATV can operate through water up to maximumrecommended depths reaching the footrests. Before fordingstreams always: 1. Determine water depths and current.2. Choose a crossing where both banks have gradual inclines.3. Proceed slowly, avoiding r...

79 RIDING Safe Riding Tips Trail Obstacles Keep Alert! Look ahead and learn to read the trail as you ride. Stay on the rightside of the trail, if possible, and be constantly alert for hazards such aslogs, rocks and low hanging branches. Not all obstacles are visible. Travel with caution on trails.se...

80 RIDING Safe Riding Tips Backing Up 1. Avoid backing up on steep inclines.2. Always 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.6. Never activate override button while throttle i...

81 RIDING Safe Riding Tips Parking on an Incline Whenever the Vehicle is Parked 1. Turn the engine off.2. Place the transmission in park.3. Set the parking brake.4. Avoid parking on an incline. If it is necessary to park on an incline, always block the rear wheels on the down hill side asshown above...

82 MAINTENANCE AND LUBRICATION Periodic Maintenance Schedule Careful periodic maintenance will help keep your vehicle in the safest,most reliable condition. Inspection, adjustment and lubricationintervals of important components are explained in the following charton the following pages.Maintenance ...

84 MAINTENANCE AND LUBRICATION Periodic Maintenance Schedule More often under severe use, such as dirty or wet conditions to purge water or dirt contamination from grease fittings and othercritical components. Emission Control System Service (California - 4-Cycle) NOTE: Some 4-Cycle models may have ...

88 MAINTENANCE AND LUBRICATION Lubrication Recommendations Item Lube Rec Method Frequency* (1)Engine Oil PolarisPremium4 Synthet-ic 0W40 Add to proper level on dip-stick. See page 96. Check leveldaily. (2) BrakeFluid DOT 3Only Maintain level between filllines. See page 47. As required;change everytw...

89 MAINTENANCE AND LUBRICATION Lubrication Recommendations (6) Front Prop Shaft(U-Joints) (4) Front Gear Case (3) Transmission(plug) (7) Propshaft Yoke Fill plug Fill plug (5) Rear Gear Case

90 MAINTENANCE AND LUBRICATION Lubrication Recommendations (8) FrontDrive Axle (UJoint) (AWDModels) Grease + Locate grease fitting andgrease with grease gun. Every 3months or50 hours (9) Ball Joint Grease** Locate fitting on back side ofstruts and grease with greasegun. Every 3months or50 hours (10)...

91 MAINTENANCE AND LUBRICATION Lubrication Recommendations (8) Axle CardanFront Drive (11) SteeringPostBushing Upper (12) Upper ControlArm (14) Rear WheelHub BearingCarrier (15) Rear Anti-Roll Bar (13) Lower Control Arm (13) Lower Con-trol Arm (10) Front A Arm Pivot Shaft

92 MAINTENANCE AND LUBRICATION Periodic Maintenance Record Use the following chart to record periodic maintenance work: Maintenance Interval Performed Servicing Date Servicing Dealer or Person Remarks First 5 Hrs. 25 Hrs. 50 Hrs. 75 Hrs. 100 Hrs.

93 MAINTENANCE AND LUBRICATION Engine Cooling System Coolant Level The recovery bottle(1), located onthe left side of the machine, must bemaintained between the minimumand maximum levels indicated onthe recovery bottle.The engine coolant level iscontrolled or maintained by therecovery system. The re...

94 MAINTENANCE AND LUBRICATION Engine Cooling System Radiator Coolant Level Inspection NOTE: This procedure is only required if the coolingsystem has been drained formaintenance and/or repair.However, if the recovery bottlehas run dry, the level in theradiator should be inspectedand coolant added if...

95 MAINTENANCE AND LUBRICATION Engine Cooling System NOTE: Use of a non-standard pressure cap will not allow the recovery system to function properly. If the cap should needreplacement contact your dealer for the correct replacement part.To insure that the coolant maintains its ability to protect th...

96 MAINTENANCE AND LUBRICATION Lubrication 4-Cycle Premium 4 Synthetic Lubricant Polaris Premium 4 All Season Synthetic engine oil has been speciallyformulated for use in Polaris 4-cycle engines. It is a fully synthetic,high performance, multi-viscosity oil designed to provide the ultimatein lubrica...

97 MAINTENANCE AND LUBRICATION Lubrication Oil and Filter Change 1. Place vehicle on a level surface.2. Run engine two to three minutes until warm. Stop engine.3. Clean area around drain plug.4. Place a drain pan beneath engine crankcase and remove drain plug. CAUTION: Oil may be hot. Do not allow h...

98 MAINTENANCE AND LUBRICATION Lubrication Transmission Lubrication The transmission fill plug is located on the right side of the machinebehind the propshaft shield or footwell.The transmission lubricant level should be checked every six months or1000 miles (1600 km), whichever comes first. Transmi...

99 MAINTENANCE AND LUBRICATION Lubrication Front Gearcase Lubrication The front gearcase fill plug islocated as shown.The front gearcase lubricant levelshould be checked every six monthsor 1000 miles (1600 km), whichevercomes first. Front gearcase oilshould be changed annually.With the ATV on a leve...

100 MAINTENANCE AND LUBRICATION Lubrication Rear Gearcase Lubrication With the ATV on a levelsurface, remove the fill plug andvisually inspect the lubricantlevel through the fill hole (1).The lubricant level should bemaintained 1 5/8 in. from thetop of the fill plug hole. UseGL5 80-90 weight gear lu...

101 MAINTENANCE AND LUBRICATION Lubrication Oil System The oil dipstick and fill tube are located on the left side of the vehicleTo check the oil:1. Set machine on a level surface. 2. Start the engine and let it idle for 20-30seconds. 3. Stop the engine and lift the lever lock (A) onthe dipstick. Re...

102 MAINTENANCE AND LUBRICATION Filter Systems Cleaning the Main Filter NOTE: It is advisable to replace the filter when it is dirty. However, in an emergency it is permissible to clean the main filter if you observethe following practices.1. Never immerse the filter in water since dirt can be trans...

104 MAINTENANCE AND LUBRICATION Adjustments Steering Inspection The steering assembly of the machine should be checked periodicallyfor loose nuts and bolts. If loose nuts and bolts are found, have yourdealer tighten them before riding your vehicle. Camber and Caster The camber and caster are non-adj...

105 MAINTENANCE AND LUBRICATION Adjustments Toe Alignment (cont.) 2. Place stands in front of the machine, perpendicular to the rear tires.3. Tie an elastic string around the stands, making sure string just touches side surface of the rear tires on each side of machine andgoes around the stands in f...

106 MAINTENANCE AND LUBRICATION Adjustments Rear Spring Adjustment The rear shock absorber spring is adjusted by rotating the adjuster inthe direction required to increase or decrease spring tension. NOTE: Accessory springs are available through your Polaris dealer. Rear SpringAdjustmentCam

107 MAINTENANCE AND LUBRICATION Adjustments Handlebar Adjustment Your ATV has handlebars whichcan be adjusted for yourpersonal fit.1. To locate handlebar bolts, it will be necessary toremove the upper headlightpod. 2. Loosen the four bolts.3. Adjust handlebar to desired height. Be sure handlebars do...

108 MAINTENANCE AND LUBRICATION Adjustments Front Brake The front brakes are hydraulic disc brakes which are activated by thebrake lever being moved toward the handlebar. These brakes areself-adjusting and require no adjustment.The following checks are recommended to keep the brake system ingood ope...

109 MAINTENANCE AND LUBRICATION Adjustments Rear Brake The rear brake is a hydraulic disc type brake which is activated by thesame lever which activates the front brake system. The rear brakesystem is self adjusting and requires no maintenance other thanperiodic checks of the pads for wear. Pads sho...

110 MAINTENANCE AND LUBRICATION Adjustments Carburetor/Engine Idle RPM Adjustment If the engine idle speed is notsatisfactory, and all otherconditions are favorable, thecarburetor can be adjusted asfollows:1. Warm up the engine by running the vehicleapproximately fiveminutes. 2. Place the transmissi...

111 MAINTENANCE AND LUBRICATION Adjustments Important Safeguards Maintain proper tire pressure according to the tire pressure decal.Improper tire inflation may affect ATV maneuverability.Do not use improper tires. The use of non-standard size or type tiresmay affect ATV handling.Make certain the whe...

112 MAINTENANCE AND LUBRICATION Adjustments Wheel Installation 1. With the transmission in park and the parkingbrake locked, place thewheel in the correctposition on the wheelhub. Be sure the valvestem is toward the outsideand rotation arrows on thetire point toward forwardrotation. 2. Attach the wh...

113 MAINTENANCE AND LUBRICATION Adjustments Tire Inspection When replacing a tire alwaysuse original equipment sizeand type. Tire Tread Depth Always replace tires whentread depth is worn to 1/8 ″ (.3 cm) (1) or less. 1

114 MAINTENANCE AND LUBRICATION Adjustments Carburetor Adjustments If the vehicle is to be operated at various altitudes and temperatures,certain adjustments can be made to improve its operation anddriveability. Above 6000 feet (1800 m) the engine air/fuel mixturebecomes overly rich. An engine loses...

115 MAINTENANCE AND LUBRICATION Lights - Adjustment - Replacement Headlight Lamp Replacement Keep your headlights and taillights clean. Poor lighting while ridingcan result in an accident causing severe injury or death. Do not service while headlight is hot. Serious burns may result. Do not touch a ...

116 MAINTENANCE AND LUBRICATION Lights - Adjustment - Replacement Headlight Lamp Replacement 1. Remove the three screws securing 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 lightl...

117 MAINTENANCE AND LUBRICATION Lights - Adjustment - Replacement High Beam Headlight Adjustment The headlight beam can be adjusted to any position desired by turningthe adjusting knob located on the bottom right side of the headlightpod.1. Place the vehicle on a level surface with the headlight app...

118 MAINTENANCE AND LUBRICATION Lights - Adjustment - Replacement Headlight Housing Replacement 1. Lift the pod lightly while depressing the tabs.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. Remove the three scr...

119 MAINTENANCE AND LUBRICATION Lights - Adjustment - Replacement Taillight/Brakelight Lamp Replacement If the taillight/brakelight does notwork the lamp may need to bereplaced.1. Remove the taillight lens cover mounting screws. Remove thelense cover and gasket and setaside for reassembly. 2. Remove...

120 MAINTENANCE AND LUBRICATION Spark Plugs Refer to page 7 for the correct spark plug for your machine.The spark plug and its condition is indicative of engine operation. Thespark plug firing end condition should be read after the engine iswarmed up and the vehicle is driven at higher speeds. Immed...

121 MAINTENANCE AND LUBRICATION Water Immersion If it is impossible to take it to a dealer before starting, follow the stepsoutlined below. Move the ATV to dry land or at the very least, to water below the footrests. Turn the fuel valve off. Remove the spark plugs. Loosen the carburetor drain screw ...

122 MAINTENANCE AND LUBRICATION Spark Arrestor Spark Arrestor The exhaust pipe must be periodically purged of accumulated carbon asfollows:1. Remove the clean out plug (1) located on the bottom of the muffler.2. Place the transmission in neutral and start the engine. Purge accumulated carbon from th...

123 MAINTENANCE AND LUBRICATION Spark Arrestor (cont.) 4. If particles are still suspected to be in themuffler, back themachine onto anincline so the rear ofthe machine is one foothigher than the front.Set the parking brakeand block the wheels.Make sure the machineis in neutral and repeat steps 2 an...

124 MAINTENANCE AND LUBRICATION PVT System Low Range Use May Reduce PVT Operating Temperatures The basic operation of the Polaris PVT system is dependent on enginespeed and vehicle torque requirements. As engine speed increases, theforce exerted on the movable drive sheave by the flyweights alsoincr...

125 MAINTENANCE AND LUBRICATION PVT System On Polaris ATVs, the approximate gear ratio difference between highand low range is 1:2.25. This difference in gearing affects the operationof the PVT, especially at speeds less than 7 MPH, due to the system’sdependence on engine speed.For example, when ope...

126 MAINTENANCE AND LUBRICATION PVT System When To Use Low Range vs. High Range The following lists provide a guideline for when to use low rangerather than high. Low Range: Basic operation at speeds less than 7 MPH Heavy pulling Riding through rough terrain (swamps, mountains, etc.) at low ground s...

127 MAINTENANCE AND LUBRICATION Battery Replenishing the Battery Fluid A poorly maintained battery willdeteriorate rapidly. Check thebattery fluid level often. The fluidlevel should be kept between theupper and lower level marks.To refill use only distilled water.Tap water contains minerals whichare...

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

129 MAINTENANCE AND LUBRICATION Battery 1. Set the battery in its holder.2. Install the battery vent tube. It must be free from obstructions and securely installed. If not, battery gases could accumulate and cause anexplosion. The tube should be routed away from the frame and bodyto prevent corrosio...

130 MAINTENANCE AND LUBRICATION Side Panel Removal Side panel removal may be difficult until the locking tabs and receivershave been snapped and unsnapped a few times.1. Remove seat. Grasp rear of side panel nearrear cab. With a quickand firm motion, pullthe panel forward andoutward to disengagethe ...

131 MAINTENANCE AND LUBRICATION Cleaning and Storage Cleaning the ATV Keeping your ATV clean will not only improve its appearance but itcan also extend the life of various components. With a fewprecautions, your ATV can be cleaned much like an automobile. Washing the ATV If a high pressure type car ...

132 MAINTENANCE AND LUBRICATION Cleaning and Storage Storage Tips Cleaning - Outside...Make necessary repairs and then clean the ATV thoroughly with a mild soap and warm water solution to remove all dirtand grime. Don’t use harsh detergents or high pressure washers. Somedetergents deteriorate rubber...

133 MAINTENANCE AND LUBRICATION Cleaning and Storage * Fog The Engine - Remove the spark plug and add 2-3 tablespoons of Premium 4 Synthetic 0W40 engine oil. To access the plug hole use asection of clear 1/4 ″ hose and a small plastic squeeze bottle filled with the pre-measured amount of oil. Instal...

134 MAINTENANCE AND LUBRICATION Transporting Whenever the ATV is to be transported the following measures shouldbe taken.1. Turn off the engine and remove the key. It may be lost if not removed. 2. Turn the fuel valve to off.3. Be certain the fuel cap, oil cap, and seat are installed correctly.4. Al...

135 TROUBLESHOOTING Clutch Drive Belt & Cover Related Issues: Diagnosis Possible Causes Solutions/What to do Loading the ATV into a pick-up or tall trailer when in highrange. Shift transmission to low range duringloading of the ATV to prevent belt burn-ing. Starting out going up asteep incline. ...

137 TROUBLESHOOTING Procedures The following information is provided to help you identify probablecauses for questions you may have about the operation of your ATV.See your Polaris dealer with any additional questions you may have. ENGINE TURNS OVER BUT FAILS TO START No Fuel Water in Fuel Spark Plu...

141 WARRANTY LIMITED WARRANTY Polaris Industries Inc., 2100 Highway 55, Medina, MN 55340, gives aSIX MONTH LIMITED WARRANTY on all components of thePolaris All Terrain Vehicle (ATV) against defects in material orworkmanship. Polaris also gives a one year limited warranty on thefinal drive chain for ...

142 WARRANTY WARRANTY COVERAGE AND EXCLUSIONS: LIMITATIONS OF WARRANTIES AND REMEDIES The Polaris limited warranty excludes any failures that are not causedby a defect in material or workmanship. This warranty does not coveraccidental damage, normal wear and tear, abuse or improper handling.This war...

143 WARRANTY ALL IMPLIED WARRANTIES (INCLUDING BUT NOT LIMITEDTO THE IMPLIED WARRANTIES OF MERCHANTABILITY ANDFITNESS FOR A PARTICULAR PURPOSE) ARE LIMITED INDURATION TO THE ABOVE SIX MONTH WARRANTY PERIOD.POLARIS FURTHER DISCLAIMS ALL EXPRESS WARRANTIESNOT STATED IN THIS WARRANTY. Some states do no...

144 INDEX Accessories 114 . . . . . . . . . . . . . . . . . . Adjustments 104-114 . . . . . . . . . . . . . . Age Restrictions 3 . . . . . . . . . . . . . . . . Air Filter 102 . . . . . . . . . . . . . . . . . . . . All Wheel Drive 54-55 . . . . . . . . . . . . . Anti–Freeze 133 . . . . . . . . . . ...