Polaris Offroad Vehicle Sportsman S User Manual

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WARNING

The engine exhaust from this

product contains chemicals known

to cause cancer, birth defects or

other reproductive harm.

A card containing important ATV safety information should be

attached to the owner’s manual on the next page. If you cannot

locate this card, or if it has been removed, please call

1-800-342-3764 for assistance.

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We’ve created a web site just for YOU!

S Technical tips

S New product introductions

S Event schedules

S Parts and Service Manual information

S Exciting details about The Way Out

Check it out...

www.polarisindustries.com/owner

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All information in this manual is based on the latest product data and specifications

available at the time of printing. Polaris Industries Inc. reserves the right to make

product changes and improvements that may affect illustrations or explanations.

No part of this manual shall be reproduced or used without the written permission of

Polaris Industries Inc.

Printed in the U.S.A.

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WELCOME

Thank you for purchasing a Polaris vehicle, and welcome to our

world-wide family of Polaris owners. We proudly produce an exciting

line of utility and recreational products.

Polaris Recreational Vehicles

S Snowmobiles

S All-terrain vehicles (ATVs)

S Watercraft

S RANGER utility vehicles

S Victory motorcycles

Polaris Professional Series Workmobilest

S Utility Task Vehiclest (UTVs)

S Personal Task Vehiclest (PTVs)

S All-Surface Loaders (ASLs)

We believe Polaris sets a standard of excellence for all utility and

recreational vehicles manufactured in the world today. Many years of

experience have gone into the engineering, design, and development of

your Polaris vehicle, making it the finest machine we’ve ever

produced.

For safe and enjoyable operation of your vehicle, be sure to follow the

instructions and recommendations in this owner’s manual. Your

manual contains instructions for minor maintenance, but information

about major repairs is outlined in the Polaris Service Manual and

should be performed only by a Factory Certified Master Service Dealer

(MSD) Technician.

Your Polaris dealer knows your vehicle best and is interested in your

total satisfaction. Be sure to return to your dealership for all of your

service needs during, and after, the warranty period.

We also take great pride in our Parts Apparel and Accessories (PAA)

products, available through our online store at www.purepolaris.com.

Have your accessories and clothing delivered right to your door!

Polaris, Polaris The Way Out, and Workmobiles are registered

trademarks of Polaris Industries Inc.

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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 essential to the recovery and identification of your vehicle.

Remove the spare key and store it in a safe place. Your key can be

duplicated only by mating a Polaris key blank with one of your

existing keys. If both keys are lost, the ignition switch must be

replaced. See your Polaris dealer.

NOTE: Record your vehicle’s ID numbers and key number (3) in the

spaces provided.

600/700

31XX

400/500

Frame VIN:

Vehicle Model Number:

Engine Serial Number:

Key Number:

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TABLE OF CONTENTS

WELCOME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

VEHICLE IDENTIFICATION NUMBERS . . . . . . . . . . . . . . . 4

TABLE OF CONTENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

FEATURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

EMISSION CONTROL SYSTEMS . . . . . . . . . . . . . . . . . . . 68

MAINTENANCE AND LUBRICATION . . . . . . . . . . . . . . . . 69

TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117

POLARIS PRODUCTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121

SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122

WARRANTY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130

INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135

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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 Polaris at no

charge. The part number is printed on the decal.

WARNING

IF OWNER’S MANUAL IS MISSING, CONTACT

A POLARIS DEALER FOR A REPLACEMENT.

7079083

E1997, 2000

WARNING

DNever operate this vehicle on HILLS steeper than 25 degrees

25°.To prevent flipover on hilly terrain, when going up or down, use

throttle and brakes gradually.

WARNING

DREVERSE operation can be dangerous, even at low speeds.

Steering becomes difficult. To prevent flipover, avoid sudden braking

or sharp turns.

DUse OVERRIDE for reverse speed limiter with caution. To prevent loss

Operating this vehicle if you are under

the age of 16 increases your chance

of severe injury or death.

of control, never activate override button with open throttle.

DPARKING BRAKE may relax when used for more than 5 minutes.

When parking on grades, leave shift in forward.

NEVER operate this vehicle if you are

under age 16.

7079085

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SAFETY

Safety Decals and Locations

ATTENTION

Operation of this vehicle without the air

filter element will severely damage the

engine.

Clean pre-filter element often, more

frequent cleaning required in dusty

conditions. Do not operate vehicle

without pre-filter.

Specific carburetor jetting and

adjustments are required depending

on temperature and altitude. See

your Owner’s Manual.

Factory setting:

40_ to 80_ F. at 0-3000 feet

(5_ to 27_ C. at 0-900 meters).

Operation of this vehicle without engine

breather filter(s) can cause engine

damage. Consult owner’s manual or

dealer for details.

7079902

WARNING

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)

MAXIMUM WEIGHT CAPACITY (Gross Vehicle Weight)

INCLUDING MACHINE, DRIVER AND CARGO IS 1200 LBS. (545 kg).

Reduce speed and allow greater distance for braking when carrying

cargo. Overloading or carrying tall, off-center, or unsecured loads

will increase your risk of losing control. Loads should be centered,

carried as low as possible, and firmly secured to the racks. With

dual racks, load distribution 1/3 front 2/3 rear is best. For stability

on rough or hilly terrain, reduce speed and cargo. Do not block

headlight. Be careful if load extends over the side of the rack.

Read Owner’s Manual for more detailed loading information

7079084

WARNING

7077920

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SAFETY

Safety Decals and Locations

WARNING

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 death.

7078689

NO STEP

WARNING

DO NOT TOW FROM RACK OR BUMPER.

Vehicle damage or tipover may result causing severe injury

or death. Tow only from tow hooks or hitch.

Max Rack Loads: Front 90 lbs. (41 kg) Rear 180 lbs. (82 kg)

7170021

Sportsman 400/500

WARNING

DO NOT TOW FROM RACK OR BUMPER.

Vehicle damage or tipover may result causing severe injury

or death. Tow only from tow hooks or hitch.

Max Rack Loads: Front 100 lbs. (45 kg) Rear 200 lbs. (91 kg)

7170912

Sportsman 600/700

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SAFETY

Safety Decals and Locations

WARNING

ALL WHEEL

DRIVE

SWITCH

MANUFACTURED

BY: POLARIS IND INC.

Pushing reverse

override button

may cause

sudden in-

DATE:

VIN:

creases in pow-

er and traction if

too much

throttle is ap-

plied. Loss of

control or for-

ward flipover

may result, es-

pecially in

Do not push switch to

engage AWD if the rear

wheels are spinning.

This may cause severe

drive shaft and clutch

damage.

THIS VEHICLE IS AN ALL TERRAIN VEHICLE AND IS NOT

INTENDED FOR USE ON PUBLIC ROADS.

See your Owner’s

Manual.

CE VÉHICULE EST UN VÉHICULE TOUT TERRAIN

QUI NEST PAS DESTINE A ETRE UTILISE SUR LES

CHEMINS PUBLICS.

AWD. See Own-

er’s Manual.

7079780

7079604

7078470

Canadian Certification Decal

TRAILER MAX WEIGHT:

1225 LBS. (557 KG) ON LEVEL GROUND

850 LBS. (386 KG) UP TO 15° GRADE

HITCH MAX. VERTICAL WEIGHT: 120 LBS. (55KG)

7170911

Sportsman 400/500

TRAILER MAX WEIGHT:

1500 LBS. (682 KG) ON LEVEL GROUND

850 LBS. (386 KG) UP TO 15° GRADE

HITCH MAX. VERTICAL WEIGHT: 150 LBS. (68KG)

7170509

Sportsman 600/700

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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 injury.

Select an approved helmet that meets

or exceeds your state’s safety standards

and bears either the Department of

Transportation (DOT) label, the

American National Standards

Institute label (ANSI z90.1), or the

Snell Memorial Foundation label.

2. Eye Protection

Do not depend on sunglasses for

proper eye protection. A pair of

goggles or a helmet face shield offer

the best protection for your eyes. They

should be kept clean and be of

shatterproof design (bearing the

markings z2.1 or VESC 8).

3. Gloves

Off-road style gloves with knuckle pads are the best for comfort and

protection.

4. Boots

The best footwear is a pair of strong over-the-calf boots with heels, like

moto-cross boots.

5. Clothing

Always wear long sleeves and long pants to protect arms and legs.

Riding pants with kneepads and a jersey with shoulder pads provide

the best protection.

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SAFETY

Operator Safety

WARNING

Failure to follow the warnings contained in this manual can result

in severe injury or death.

A Polaris ATV is not a toy and can be hazardous to operate. This

vehicle handles differently than other vehicles, such as

motorcycles and cars. A collision or rollover can occur quickly,

even during routine maneuvers like turning, or driving on hills or

over obstacles, if you fail to take proper precautions.

Read and understand your owner’s manual and all warnings

before operating a Polaris ATV.

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.

Read and understand your owner’s manual, which includes valuable

information about all aspects of your vehicle, including safe operating

procedures.

Safety Training

When you purchased your new ATV, your dealer offered a hands-on

safety training course that covers all aspects of vehicle safety. You

were also provided with printed materials that explain safe operating

procedures. You should review this information on a regular basis.

If you purchased a used Polaris ATV from a party other than a Polaris

dealer, you can request this free safety training from any authorized

Polaris dealer.

A Polaris ATV is an off-road vehicle. Familiarize yourself with all

laws and regulations concerning the operation of this vehicle in your

area.

We strongly advise you to strictly follow the recommended

maintenance program outlined in your owner’s manual. This

preventive maintenance program is designed to ensure that all critical

components on your vehicle are thoroughly inspected at specific

intervals.

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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, alerts

you to the potential for personal injury.

WARNING

The safety alert warning indicates a potential hazard that may result

in serious injury or death.

CAUTION

The safety alert caution indicates a potential hazard that may result

in minor personal injury or damage to the vehicle.

CAUTION

A caution indicates a situation that may result in damage to the

vehicle.

NOTE:

A note will alert you to important information or instructions.

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SAFETY

Operator Safety

WARNING

Serious injury or death can result if you do not follow these

instructions and procedures, which are outlined in further detail

within your owner’s manual.

S Read this manual and all labels carefully, and follow the operating

procedures described.

S Never operate an ATV without proper instruction. Take a training

course. Beginners should receive training from a certified instructor.

Contact an authorized Polaris ATV dealer or call Polaris at

1-800-342-3764 to find out about the training courses nearest you.

S Never allow anyone under 16 years of age to operate this ATV.

S Never permit a guest to operate the ATV unless the guest has read

this manual and all product labels and has completed a certified safe-

ty training course.

S Always avoid operating an ATV on paved surfaces, including side-

walks, driveways, parking lots, and streets.

S Never operate an ATV on a public street, road or highway, including

a dirt or gravel road.

S Never operate an ATV without wearing an approved helmet that fits

properly. Always wear eye protection (goggles or face shield),

gloves, boots, a long-sleeved shirt or jacket, and long pants.

S Never consume alcohol or drugs before or while operating an ATV.

S Never operate at excessive speeds. Travel at speeds appropriate for

the terrain, visibility and operating conditions, and your experience.

S Never attempt wheelies, jumps or other stunts.

S Always inspect your ATV before each use to make sure it’s in safe

operating condition. Always follow the inspection and maintenance

procedures and schedules outlined in your owner’s manual.

S Always keep both hands on the handlebars and both feet on the foot-

rests of the ATV during operation.

S Always travel slowly and use extra caution when operating on unfa-

miliar terrain. Be alert to changing terrain conditions.

S Never operate on excessively rough, slippery, or loose terrain.

S Always follow proper turning procedures as described in this manu-

al. Practice turning at low speeds before attempting to turn at faster

speeds. Do not turn at excessive speeds.

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SAFETY

Operator Safety

S Always have the ATV inspected by an authorized Polaris dealer if

it’s been involved in an accident.

S Never operate on hills too steep for the ATV or for your abilities.

Practice on smaller hills before attempting larger hills.

S Always follow proper procedures for climbing hills. Check the ter-

rain carefully before ascending a hill. Never climb hills with exces-

sively slippery or loose surfaces. Shift your weight forward. Never

open the throttle suddenly or make sudden gear changes. Never go

over the top of a hill at high speed.

S Always follow proper procedures for going downhill and for braking

on hills. Check the terrain carefully before you start down a hill.

Shift your weight backward. Never go down a hill at high speed.

Avoid going down a hill at an angle, which would cause the vehicle

to lean sharply to one side. Travel straight down the hill when pos-

sible.

S Always follow proper procedures for crossing the side of a hill.

Avoid hills with excessively slippery or loose surfaces. Shift your

weight to the uphill side of the ATV. Never attempt to turn the ATV

around on any hill until you’ve mastered (on level ground) the turn-

ing technique outlined in this manual. Avoid crossing the side of a

steep hill when possible.

S Always use proper procedures if you stall or roll backwards while

climbing a hill. To avoid stalling, maintain a steady speed when

climbing a hill. If you stall or roll backwards, follow the special

procedure for braking described in this manual. Always dismount

on the uphill side, or to either side if the ATV is pointed straight

uphill. Turn the ATV around and remount following the procedure

described in this manual.

S Always check for obstacles before operating in a new area. Never

attempt to operate over large obstacles, such as rocks or fallen trees.

Always follow proper procedures when operating over obstacles as

described in this manual.

S Always be careful of skidding or sliding. On slippery surfaces like

ice, travel slowly and use extra caution to reduce the chance of skid-

ding or sliding out of control.

S Avoid operating the ATV through deep or fast-flowing water. If it’s

unavoidable, travel slowly, balance your weight carefully, avoid sud-

den movements, and maintain a slow and steady forward motion. Do

not make sudden turns or stops, and do not make sudden throttle

changes.

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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 proceed in reverse, move slowly

and avoid turning at sharp angles.

S Always use the size and type of tires specified for your ATV, and

always maintain proper tire pressure.

S Never modify an ATV through improper installation or use of acces-

sories.

S Never exceed the stated load capacity for your ATV. Cargo must be

properly distributed and securely attached. Reduce speed and follow

the instructions in this manual for carrying cargo or towing. Allow a

greater distance for braking.

FOR MORE INFORMATION ABOUT ATV SAFETY, call the Con-

sumer Product Safety Commission at 1-800-638-2772, or call

Polaris at 1-800-342-3764.

Equipment Modifications

We are concerned for the safety of our customers and for the general

public. Therefore, we strongly recommend that consumers do not

install on a Polaris ATV any equipment that may increase the speed or

power of the vehicle, or make any other modifications to the vehicle

for these purposes. Any modifications to the original equipment of the

vehicle create a substantial safety hazard and increase the risk of bodily

injury.

The warranty on your Polaris ATV is terminated if any equipment has

been added to the vehicle, or if any modifications have been made to

the vehicle, that increase its speed or power.

NOTE: The addition of certain accessories, including (but not limited

to) mowers, blades, tires, sprayers, or large racks, may change the

handling characteristics of the vehicle. Use only Polaris-approved

accessories, and familiarize yourself with their function and effect on

the vehicle.

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SAFETY

Operator Safety

WARNING

POTENTIAL HAZARD

Operating this ATV without proper instruction.

WHAT CAN HAPPEN

The risk of an accident is greatly increased if the operator

does not know how to operate the ATV properly in different

situations and on different types of terrain.

HOW TO AVOID THE HAZARD

Beginning and inexperienced operators should complete the

certified training course offered by Polaris. Operators should

regularly practice the skills learned in the course and the

operating techniques described in the owner’s manual.

For more information about the training course, contact an

authorized ATV dealer or call Polaris at 1-800-342-3764.

WARNING

POTENTIAL HAZARD

Failure to follow the age recommendations for this ATV.

WHAT CAN HAPPEN

Severe injury and/or death could occur if a child under the

minimum age recommendation operates an ATV.

Even though a child may be within the recommended age group

for operating some ATVs, he/she may not have the skills,

abilities, or judgment needed to operate an ATV safely and could

be susceptible to accident or injury.

HOW TO AVOID THE HAZARD

No one under the age of 16 should operate a Polaris ATV.

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SAFETY

Operator Safety

WARNING

POTENTIAL HAZARD

Carrying a passenger on an ATV.

WHAT CAN HAPPEN

Carrying a passenger greatly reduces the operator’s ability to

balance and control the ATV, which could cause an accident

and injury to the operator and/or passenger.

HOW TO AVOID THE HAZARD

Never carry a passenger. The purpose of the long seat is to

allow the operator to shift position as needed during operation.

It is not intended for carrying passengers.

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SAFETY

Operator Safety

WARNING

POTENTIAL HAZARD

Operating an ATV on paved surfaces, including sidewalks,

paths, parking lots, and driveways.

WHAT CAN HAPPEN

ATV tires are designed for off-road use. Operating on paved

surfaces may adversely affect the handling of the ATV and

could result in loss of control, accident, and/or injury.

HOW TO AVOID THE HAZARD

Avoid operating the ATV on pavement. If it’s unavoidable,

travel slowly and avoid sudden turns or stops.

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SAFETY

Operator Safety

WARNING

POTENTIAL HAZARD

Operating this ATV on public streets, roads or highways.

WHAT CAN HAPPEN

The ATV could collide with another vehicle.

HOW TO AVOID THE HAZARD

Never operate the ATV on any public street, road or highway,

including dirt and gravel roads. In many states it’s illegal to

operate ATVs on public streets, roads and highways.

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SAFETY

Operator Safety

WARNING

POTENTIAL HAZARD

Operating this ATV without wearing an approved helmet, eye

protection and protective clothing.

WHAT CAN HAPPEN

Operating an ATV without an approved helmet increases the

risk of a severe head injury or death in the event of an

accident.

Operating without eye protection could result in an accident

and could increase the chance of a severe injury in the event

of an accident.

HOW TO AVOID THE HAZARD

Always wear an approved helmet that fits properly.

Always wear eye protection (goggles or face shield), gloves,

boots, long-sleeved shirt or jacket, and long pants.

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SAFETY

Operator Safety

WARNING

POTENTIAL HAZARD

Operating the ATV after consuming alcohol or drugs.

WHAT CAN HAPPEN

Consumption of alcohol and/or drugs could seriously affect

operator judgment. Reaction time may be slower and operator

balance and perception could be affected.

Consuming alcohol and/or drugs before or while operating an

ATV could result in an accident causing severe injury or death.

HOW TO AVOID THE HAZARD

Never consume alcohol or drugs before or while operating an

ATV.

WARNING

POTENTIAL HAZARD

Operating the ATV at excessive speeds.

WHAT CAN HAPPEN

Excessive speed increases the operator’s chance of losing

control of the ATV, which can result in an accident causing

severe injury or death.

HOW TO AVOID THE HAZARD

Always operate the ATV at a speed that’s proper for the terrain,

visibility and operating conditions, and your experience.

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SAFETY

Operator Safety

WARNING

POTENTIAL HAZARD

Attempting wheelies, jumps and other stunts.

WHAT CAN HAPPEN

Attempting stunts increases the chance of an accident, including

an overturn.

HOW TO AVOID THE HAZARD

Never attempt wheelies, jumps, or other stunts. Avoid exhibition

driving.

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SAFETY

Operator Safety

WARNING

POTENTIAL HAZARD

Failure to inspect the ATV before operating.

Failure to properly maintain the ATV.

WHAT CAN HAPPEN

Poor maintenance increases the possibility of an accident or

equipment damage.

HOW TO AVOID THE HAZARD

Always inspect your ATV before each use to make sure it’s in

safe operating condition.

Always follow the inspection and maintenance procedures and

schedules described in the owner’s manual.

WARNING

POTENTIAL HAZARD

Removing hands from the handlebars or feet from the

footrests during operation.

WHAT CAN HAPPEN

Removing even one hand or foot can reduce ability to

control the vehicle or could cause loss of balance and

ejection from the ATV.

If the operator’s foot is not firmly planted on the footrest, it

could come into contact with the rear wheels and lead to

accident or injury.

HOW TO AVOID THE HAZARD

Always keep both hands on the handlebars and both feet

on the footrests of the ATV during operation.

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SAFETY

Operator Safety

WARNING

POTENTIAL HAZARD

Failure to use extra caution when operating the ATV on unfamiliar

terrain.

WHAT CAN HAPPEN

Unfamiliar terrain may contain hidden rocks, bumps, or holes that

could cause loss of control or overturn.

HOW TO AVOID THE HAZARD

Travel slowly and use extra caution when operating on unfamiliar

terrain. Always be alert to changing terrain conditions.

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SAFETY

Operator Safety

WARNING

POTENTIAL HAZARD

Failure to use extra caution when operating on excessively

rough, slippery or loose terrain.

WHAT CAN HAPPEN

Operating on excessively rough, slippery or loose terrain could

cause loss of traction or loss of control, which could result in an

accident or overturn.

HOW TO AVOID THE HAZARD

Do not operate on excessively rough, slippery or loose terrain

until you’ve learned and practiced the skills necessary to

control the ATV on such terrain.

Always use extra caution on rough, slippery or loose terrain.

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SAFETY

Operator Safety

WARNING

POTENTIAL HAZARD

Turning improperly.

WHAT CAN HAPPEN

Improper turns could cause loss of control and lead to a collision

or overturn.

HOW TO AVOID THE HAZARD

Always follow proper procedures for turning as described in the

owner’s manual.

Practice turning at slow speeds before attempting to turn at

faster speeds.

Never turn at excessive speed.

WARNING

POTENTIAL HAZARD

Operating on excessively steep hills.

WHAT CAN HAPPEN

The vehicle may overturn.

HOW TO AVOID THE HAZARD

Never operate on hills too steep for the ATV or for your

abilities. Never operate the ATV on hills steeper than 25_.

Practice on smaller hills before attempting large hills.

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SAFETY

Operator Safety

WARNING

POTENTIAL HAZARD

Climbing hills improperly.

WHAT CAN HAPPEN

Improper hill climbing could cause loss of control or overturn.

HOW TO AVOID THE HAZARD

Always follow proper procedures for climbing hills as described

in the owner’s manual.

Always check the terrain carefully before ascending any hill.

Never operate the ATV on hills steeper than 25_.

Never climb hills with excessively slippery or loose surfaces.

Shift your weight forward.

Never open the throttle suddenly while traveling uphill. The ATV

could flip over backwards.

Never go over the top of any hill at high speed. An obstacle, a

sharp drop, or another vehicle or person could be on the other

side of the hill.

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SAFETY

Operator Safety

WARNING

POTENTIAL HAZARD

Traveling downhill improperly.

WHAT CAN HAPPEN

Improperly descending a hill could cause loss of control or

overturn.

HOW TO AVOID THE HAZARD

Always follow proper procedures for traveling down hills as

described in the owner’s manual. NOTE: A special technique

is required when braking while traveling downhill. See page 62.

Always check the terrain carefully before descending a hill.

Shift your weight backward.

Never travel down a hill at high speed.

Avoid traveling down a hill at an angle, which would cause the

vehicle to lean sharply to one side. Travel straight down the hill

when possible.

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SAFETY

Operator Safety

WARNING

POTENTIAL HAZARD

Improperly crossing hills and turning on hills.

WHAT CAN HAPPEN

Improperly crossing or turning as hills could cause loss of control

or overturn.

HOW TO AVOID THE HAZARD

Never attempt to turn the ATV around on any hill until you’ve

mastered the turning technique (on level ground) as described in

the owner’s manual. See page 63. Use extra caution when

turning on any hill.

Avoid crossing the side of a steep hill.

When crossing the side of a hill:

Always follow proper procedures as described in the owner’s

manual.

Avoid hills with excessively slippery or loose surfaces.

Shift your weight to the uphill side of the ATV.

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SAFETY

Operator Safety

WARNING

POTENTIAL HAZARD

Stalling, rolling backwards or

improperly dismounting while

climbing a hill.

WHAT CAN HAPPEN

The vehicle could overturn.

HOW TO AVOID THE

HAZARD

Maintain steady speed when

climbing a hill.

If all forward speed is lost:

Keep your weight uphill.

Apply the brakes.

Lock the parking brake when fully stopped.

If the ATV begins rolling backwards:

Keep weight uphill.

Never apply engine power.

Never apply the rear brake while rolling backwards.

Apply the single-lever brake gradually.

When fully stopped, apply the rear brake as well, and then lock

the parking brake.

Dismount on uphill side, or to either side if ATV is pointed

straight uphill.

Turn the ATV around and remount, following the procedure

described in the owner’s manual. See page 63.

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SAFETY

Operator Safety

WARNING

POTENTIAL HAZARD

Improperly operating over obstacles.

WHAT CAN HAPPEN

Operating over obstacles could cause loss of control or overturn.

HOW TO AVOID THE HAZARD

Before operating in a new area, check for obstacles.

Avoid operating over large obstacles such as rocks and fallen

trees when possible. If unavoidable, use extreme caution and

always follow proper procedures as outlined in the owner’s

manual.

WARNING

POTENTIAL HAZARD

Skidding or sliding.

WHAT CAN HAPPEN

Skidding or sliding can cause loss of control.

If the tires regain traction unexpectedly, the ATV could overturn.

HOW TO AVOID THE HAZARD

On slippery surfaces such as ice, travel slowly and use extra

caution to reduce the chance of skidding or sliding out of control.

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SAFETY

Operator Safety

WARNING

POTENTIAL HAZARD

Operating the ATV through deep or fast-flowing water.

WHAT CAN HAPPEN

Tires may float, causing loss of traction and loss of control,

which could lead to an accident or overturn.

HOW TO AVOID THE HAZARD

Avoid operating the ATV through deep or fast-flowing water.

If it’s unavoidable to enter water that exceeds the

recommended maximum depth (see page 64), travel slowly,

balance your weight carefully, avoid sudden movements, and

maintain a slow and steady forward motion. Do not make

sudden turns or stops, and do not make sudden throttle

changes.

Wet brakes may have reduced stopping ability. Always test

the brakes after leaving water. If necessary, apply them

several times to let friction dry out the pads.

WARNING

POTENTIAL HAZARD

Improperly operating in reverse.

WHAT CAN HAPPEN

The ATV could collide with an obstacle or person, resulting in

severe injury.

HOW TO AVOID THE HAZARD

Before shifting into reverse gear, always check for obstacles or

people behind the ATV. When it’s safe to proceed, back

slowly.

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SAFETY

Operator Safety

WARNING

POTENTIAL HAZARD

Operating this ATV with improper tires, or with improper or uneven

tire pressure.

WHAT CAN HAPPEN

Use of improper tires, or operation of the ATV with improper or

uneven tire pressure, could cause loss of control or accident.

HOW TO AVOID THE HAZARD

Always use the size and type of tires specified for the ATV in the

owner’s manual.

Always maintain proper tire pressure as described in the owner’s

manual and on safety decals.

WARNING

POTENTIAL HAZARD

Operating the ATV with improper modifications.

WHAT CAN HAPPEN

Improper installation of accessories or modification of the ATV

may cause changes in handling, which could lead to an

accident.

HOW TO AVOID THE HAZARD

Never modify the ATV through improper installation or use of

accessories. All parts and accessories added to the vehicle

must be genuine Polaris Industries Inc. or equivalent

components designed for use on this ATV and should be

installed and used according to approved instructions. See

your authorized Polaris ATV dealer for more information.

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SAFETY

Operator Safety

WARNING

POTENTIAL HAZARD

Overloading the ATV or carrying/towing cargo improperly.

WHAT CAN HAPPEN

Overloading and towing can cause changes in vehicle handling,

which could lead to loss of control or an accident.

HOW TO AVOID THE HAZARD

Never exceed the stated load capacity for this ATV.

Cargo should be properly distributed and securely attached.

Reduce speed when carrying cargo or pulling a trailer. Allow a

greater distance for braking.

Always follow the instructions in the owner’s manual for carrying

cargo or pulling a trailer.

WARNING

POTENTIAL HAZARD

Operating on frozen bodies of water.

WHAT CAN HAPPEN

Severe injury or death can result if the ATV and/or the operator

fall through the ice.

HOW TO AVOID THE HAZARD

Never operate the ATV on a frozen body of water. If you’re

confident that the ice is thick enough and sound enough to

support the machine and its operator, as well as the force

created by a moving vehicle, exercise extreme caution.

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SAFETY

Operator Safety

WARNING

Operating a damaged ATV can result in an accident with serious

injury or death. After any overturn or accident, have a qualified

service dealer inspect the entire machine for possible damage,

including (but not limited to) brakes, throttle and steering

systems.

WARNING

Safe operation of this rider-active vehicle requires good judgement

and physical skills. Persons with cognitive or physical disabilities

who operate this vehicle have an increased risk of overturn and

loss of control, which could result in severe injury or death.

CAUTION

Exposure to the hot components could result in a fire. Always

keep combustible materials away from the exhaust system.

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CONTROLS

Engine Electrical Switches

WARNING

Activating the override switch while the throttle is open can cause

loss of control, resulting in severe injury or death. Do not activate

the override switch while the throttle is open.

Mode/Reverse Override Switch (1) - This vehicle is equipped with a

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 AWD switch is

on. This switch is also used to toggle through the different modes of

the rider information center. See page 45.

Engine Stop Switch (2) - The engine will

OFF

RUN

not start or run when the switch is in the

OFF position. Its purpose is to provide the

operator with a quick means of engine

shutdown in case of an emergency.

Main Switch (3) - To start the engine, slide

the stop switch to the center RUN position and turn the main key

switch clockwise past the ON position. Release the key when the

engine starts.

NOTE: Both the main switch and the emergency engine stop switch

will shut off all electrical power to the vehicle, including lights. To

stop the engine, slide the stop switch either right or left to the OFF

position.

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CONTROLS

WARNING

Operating an ATV with sticking or improperly operating throttle

controls could cause an accident and lead to severe injury or

death.

Never start or operate an ATV with a sticking or improperly

operating throttle. Always contact your dealer for service if throttle

problems arise.

Failure to check or maintain proper operation of the throttle

system can result in an accident if the throttle lever sticks during

operation. Always check the lever for free movement and return

before starting the engine. Also check occasionally during

operation.

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 reduce the risk of a frozen or stuck throttle. If the

throttle cable should stick in an open position when the operator

releases the throttle lever, the engine will stop, and power to the rear

wheels will cease.

WARNING

The Electronic Throttle Control (ETC) stops the engine in the

event of a throttle system malfunction and is provided for your

safety. Do not attempt to modify the ETC system or replace it

with any after market throttle mechanisms.

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CONTROLS

Light Switches

The light switch is located on the left handlebar. It’s used to turn the

lights on and off and to switch the lights from HI to LO. NOTE: The

lights won’t work unless the key is in the ON position and the shut-off

switch is in the RUN position.

WARNING

Operating the ATV on streets or roads, especially in darkness,

could result in an accident and serious injury or death.

Your ATV is not equipped with highway-approved lights. It’s

designed for and must be used for off-road use only. Use caution

and drive at reduced speeds in conditions of reduced visibility such

as fog, rain and darkness.

Brake Lever

The front and rear brakes are applied

by squeezing the brake lever (1)

toward the handlebar. The front and

rear brakes are hydraulically

activated disc type brakes that are

activated by only one lever.

Always test brake lever travel and

master cylinder fluid level before riding.

When squeezed, the lever should feel firm. Any sponginess would

indicate a possible fluid leak or low master cylinder fluid level, which

must be corrected before riding. Contact your dealer for proper

diagnosis and repairs.

WARNING

Operating the ATV with a spongy brake lever can result in loss

of braking, which could cause an accident.

Never operate the ATV with a spongy-feeling brake lever.

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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. When

fluid needs to be added, the eye will be clear.

NOTE: When checking the fluid level, the ATV must be on level

ground with the handlebars straight. If the fluid level is low add DOT 3

brake fluid only. See page 121 for the part numbers of Polaris products.

WARNING

After opening a bottle of brake fluid, always discard any

unused portion. Never store or use a partial bottle. Brake

fluid is hygroscopic, meaning it rapidly absorbs moisture from

the air. The moisture causes the boiling temperature of the

brake fluid to drop, which can lead to early brake fade and the

possibility of accident or severe injury.

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CONTROLS

Parking Brake

WARNING

Operating the ATV while the parking brake is engaged could

result in an accident and serious injury or death. Always check

to be sure the parking brake is disengaged before operating.

Setting the Parking Brake

1. Place the transmission in 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 release the parking brake

lock, squeeze and release the brake

lever. It will return to its unlocked position.

Important Safeguards

S The parking brake may relax if left on for a long period of time. Al-

ways block the wheels to prevent rolling.

S Always block the wheels on the downhill side of the ATV if leaving

it parked on a hill. Another option is to park the ATV in a sidehill

position.

S Never depend on the parking brake alone if the ATV is parked on a

hill. Always block the wheels to prevent rolling.

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CONTROLS

Auxiliary Brake

WARNING

Aggressively applying the auxiliary brake when backing down a

hill may cause rear tipover, which could result in serious injury or

death.

Use caution when applying the auxiliary brake. Do not

aggressively apply the auxiliary brake when going forward. The

rear wheels may skid and slide sideways, causing loss of control

and serious injury or death.

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 slide while

using the auxiliary brake,

reduce brake pedal pressure to brake the rear wheels without skidding.

Brake Fluid Level

Check the brake fluid level frequently for the auxiliary brake system.

The reservoir is located under the seat or near the auxiliary brake.

Maintain the fluid level between the maximum and minimum marks.

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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

RES

The fuel valve (1) is located on the left side

panel. It has three positions:

OFF: For vehicle storage and when transporting.

OFF

ON: For normal operation.

RES: For reserve supply if main supply is

exhausted.

NOTE: There’s about a 7 to 10 mile

(11.2 to 16 km) range on reserve gas.

Always refill the gas tank as soon as

possible after using the main supply.

Always return the valve to the on position

after refueling.

Fuel Tank

The fuel tank filler cap (2) is located directly

below the handlebar. Use either leaded or

unleaded gasoline with a minimum pump octane

number of 87=(R+ M/2) octane.

Fuel Filter

The in-line fuel filter should be replaced by your dealer after every 100

hours of operation, or annually. Do not attempt to clean the fuel filter.

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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 or 700, you must

first apply the auxiliary brake to activate the high/park lock-out

mechanism. When shifting out of HIGH or PARK, it’s not necessary

to apply the brake.

400/500

600/700

CAUTION

Shifting gears with the engine speed above idle or while the

vehicle is moving could cause transmission damage.

To change gears, stop the vehicle, and with the engine idling,

move the lever to the desired gear. Apply the auxiliary brake if

shifting into HIGH or PARK on the Sportsman 600 or 700.

Whenever the ATV is left unattended, always place the transmission in

first gear (or in PARK if equipped) and lock the parking brake.

Maintaining shift linkage adjustment is important to assure proper

transmission function on the Sportsman 400 and 500. See your dealer

if you experience any shifting problems.

Belt Life

To extend belt life, use low forward gear in heavy pulling situations and

when operating at less than seven miles per hour for extended periods of

time.

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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

AWD indicator light in the

instrument cluster will be on.

When in AWD, the front gearcase will automatically engage any time

the rear wheels lose traction. When the rear wheels regain traction, the

front gearcase will automatically disengage.

NOTE: The override switch allows activation of AWD in reverse if

the AWD switch is on. See page 36.

There is no limit to the length of time the vehicle may remain in AWD.

Engaging Front Gearcase

The AWD switch may be turned on or off while the vehicle is moving.

Initially, the vehicle’s electronic system will not enable the AWD until

the engine RPM is below 3100. Once enabled, the AWD remains

enabled until the AWD switch is turned off. If the switch is turned off

while the front gearcase is moving, it will not disengage until the rear

wheels regain traction.

Engage the AWD switch before getting into conditions where front

wheel drive may be needed. If the rear wheels are spinning, release the

throttle before switching to AWD.

CAUTION

Switching to AWD while the rear wheels are spinning may cause

severe drive shaft and gearcase damage. Always switch to AWD

while the rear wheels have traction or are at rest.

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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

approximately 7-9 mph. Refer to page 36 for additional information.

1. Rider Information Center

2. Speedometer needle - in addition to showing vehicle speed, the

needle flashes when a warning condition exists.

3. Speedometer

CAUTION

To prevent damage, wash the ATV by hand or with a garden hose

using mild soap. Do not use alcohol to clean the instrument

cluster. Immediately clean off any gasoline that splashes on the

instrument cluster.

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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 may have

shut off to protect the electrical system. If this occurs, take the ATV to

your Polaris dealer for proper diagnosis.

1. Gear Indicator - As the shift lever is moved, this indicates the

gear the transmission is in:

H = High Range

L = Low Range

N = Neutral

R = Reverse

P = Park (if equipped)

2. AWD Indicator - This

indicator illuminates

when the electrical

portion of the AWD

system is enabled.

3. Engine Hour Display Indicator

4. Service Interval/Diagnostic Mode Indicator

5. Low Battery and Over Voltage - This warning usually indicates

that the ATV is being operated at an RPM too low to keep the

battery charged. A low battery warning may also occur under normal

operation if the machine is at idle and high electrical load (lights,

cooling fan, accessories) is applied. Driving at a higher RPM or

connecting a battery charger will usually clear the warning.

6. Odometer/Tachometer/Tripmeter/ Hour Meter

7. Check Engine Warning Indicator - The word HOT will display

alphanumerically when the engine is overheating. Do not continue

to operate the ATV if this warning appears or serious engine

damage could result.

8. Mode Indicator

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FEATURES

Instrument Cluster

Rider Information Center

The rider information center has 4 standard modes:

Mode 1 - Odometer

Mode 2 - Tripmeter

Mode 3 - Total Service Hours

Mode 4 - Tachometer

The reverse override button on the left handlebar is also the mode

button. NOTE: If using the mode button to program the rider

information center, or to toggle through the options, the machine

cannot be in reverse.

Mode 1 - Odometer

The odometer records the miles traveled by the ATV.

Mode 2 -Trip Meter

The trip meter records the miles traveled by the ATV on each trip if it’s

reset before each trip. To reset the trip meter, select the trip meter

mode. Press and hold the mode button (override button) until the total

changes to 0 . NOTE: In the Rider Information Center, the trip meter

display contains a decimal point, but the odometer displays without a

decimal point.

Mode 3 - Hour Meter

This mode logs the total hours the engine has been in operation.

Mode 4 - Tachometer

The engine RPM is displayed digitally. NOTE: Small fluctuations in

the RPM from day to day may be normal because of changes in

humidity, temperature and elevation.

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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, either shift the machine out of neutral or

turn the key switch off and on. NOTE: Any movement of the tires

will also take the machine out of the diagnostic mode.

To enter the diagnostics mode:

1. Turn the key switch off and wait 10 seconds.

2. Set the park brake and shift the transmission to neutral.

3. Hold the mode/reverse override button and turn the key switch on.

4. Release the switch as soon as the display is activated.

The initial screen display refers to the software version installed in

your ATV. This information is displayed briefly.

Use the mode/reverse override button to toggle through the diagnostic

screens.

Screen 1: Battery voltage

Screen 2: Tachometer

Screen 3: AWD diagnostic

This gauge indicates whether or not current is flowing through the

AWD coil (only on models with switchable AWD).

Screen 4: Gear circuit diagnostic

This screen displays the resistance value (in ohms) being read at the

gear switch input of the gauge.

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FEATURES

Instrument Cluster

Rider Information Center

Diagnostic Mode

Screen 5: Programmable service interval

The purpose of the programmable service interval is to provide the

consumer and dealer with a convenient reminder for routine

maintenance. When your vehicle leaves the factory, this feature is set at

50 hours. You must enable the programmable service interval before it

can be used.

Once the service interval mode is set with the hours when service is

due, the hours of actual engine operation are subtracted from the set

hours until 0 is reached. When the counter reaches 0, the wrench icon

will flash quickly for 5 seconds each time the vehicle is started as a

reminder that the periodic maintenance is due.

To set the hours, press and hold the mode/override button until the

wrench icon flashes. When it begins to flash, release the button. The

setting will increase by one hour each time the button is pressed.

Pressing and holding the button will allow the numbers to escalate

much faster. When the desired time increment is displayed, release the

button and wait for the wrench to stop flashing. When the wrench

stops blinking, your service hours are set. NOTE: If you scroll past

the intended number, hold the button down until the count turns over to

0. You can then reset the number.

If the service interval is enabled on your ATV and you wish to turn it

off, toggle to the service interval mode. Press and hold the mode

button for approximately 7 seconds until the word OFF appears in the

Rider Information Center.

Screen 6: Miles/Kilometers toggle

The display in the tripmeter and odometer can be changed to display

either kilometers or miles. The current display mode will be shown as

KM or MP. To change, hold in the mode button until the letters flash,

then press and release the button once. When the display stops

flashing, the mode has been set.

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OPERATION

Fuel Safety

WARNING

Gasoline is highly flammable and explosive under certain

conditions.

S Always exercise extreme caution whenever handling gasoline.

S Always refuel with the engine stopped, and outdoors or in a

well ventilated area.

S Do not smoke or allow open flames or sparks in or near the

area where refueling is performed or where gasoline is stored.

S Do not overfill the tank. Do not fill the tank neck.

S If gasoline spills on your skin or clothing, immediately wash it

off with soap and water and change clothing.

S Never start the engine or let it run in an enclosed area. Engine

exhaust fumes are poisonous and can cause loss of con-

sciousness or death in a short time.

S Turn the fuel valve off whenever the ATV is stored or parked.

WARNING

The engine exhaust from this product contains chemicals known

to cause cancer, birth defects or other reproductive harm.

Operate this vehicle only outdoors or in well-ventilated areas.

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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 treatment of a new

engine will result in more efficient performance and longer life for the

engine. Perform the following procedures carefully.

CAUTION

Excessive heat build-up during the first three hours of operation will

damage close-fitted engine parts. Do not operate at full throttle or

high speeds for extended periods during the first three hours of use.

CAUTION

Mixing brands or using a non-recommended oil may cause

serious engine damage. We recommend the use of Polaris

Premium 4 synthetic Oil or another 0W-40 API certified SH oil.

Never substitute or mix oil brands.

1. Fill the fuel tank with gasoline. See page 42.

2. Check the oil reservoir level on the dipstick. See page 79. Add

oil if necessary to maintain the level between the safe and add

marks.

3. Drive slowly at first. Select an open area that allows room to

familiarize yourself with vehicle operation and handling.

4. Vary the throttle positions. Do not operate at sustained idle.

5. Perform regular checks on fluid levels, controls and areas outlined

on the daily pre-ride inspection checklist. See page 52.

6. Pull only light loads.

7. During the break-in period, change both the oil and the filter at 20

hours or 200 miles.

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OPERATION

Pre-Ride Inspection

WARNING

If a proper inspection is not done before each use, severe injury or

death could result. Always inspect the vehicle before each use to

ensure it’s in proper operating condition.

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 operation, adjustment and fluid levels (includes

auxiliary brake).

4. Throttle - Check for free operation and closing.

5. Headlight/Taillight/Brakelight - Check operation of all indicator

lights and switches.

6. Engine stop switch - Check for proper function.

7. Wheels - Check for tightness of wheel nuts and axle nuts; check

that axle nuts are secured by cotter pins.

8. Air cleaner element - Check for dirt; clean or replace.

9. Steering - Check for free operation, noting any unusual looseness

in any area.

10. Loose parts - Visually inspect the vehicle for any damaged

components or loose nuts/bolts or fasteners.

11. Riding gear - Wear a helmet, goggles and protective clothing.

12. Engine coolant - Check for proper level at the recovery bottle.

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OPERATION

Starting the Engine

Starting a Cold Engine

WARNING

Engine exhaust contains poisonous carbon monoxide and can

cause loss of consciousness resulting in severe injury or death.

Never run an engine in an enclosed area.

1. Place the transmission in 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 pulled

completely out. The choke is off

when the knob is pushed completely in. The choke can be adjusted

gradually, depending on how much choke is needed for starting. Be

sure the choke is off during operation, as excess fuel washing into the

engine oil will increase wear on engine components.

4. Turn the engine stop switch to RUN.

NOTE: Do not press the throttle while starting the engine.

5. Turn the ignition key past the ON position to engage the starter.

Activate the starter for a maximum of five seconds, releasing the

key when the vehicle starts. If the engine does not start, release the

starter and wait five seconds. Activate the starter for another five

seconds if necessary. Repeat this procedure until the engine starts.

6. If the engine slows or stops, position the choke knob half way in to

allow proper engine warm-up.

7. Vary the engine RPM slightly with the throttle to aid in warm-up.

When the engine idles smoothly, push the choke completely in.

CAUTION

Operating the vehicle immediately after starting could cause engine

damage. Allow the engine to warm up for several minutes before

operating the vehicle.

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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 brake, turn the fuel tank valve on, sit on the

vehicle, and turn the engine stop switch to RUN.

3. If the engine has cooled to a point where it does not readily start,

intermittent use of the choke button (pulled half way out) may be

necessary.

4. If the engine is over-choked when warm, depress the throttle lever

fully while cranking to aid in starting.

5. Release the throttle lever immediately after the engine starts. If the

engine does not start and all conditions are favorable, change the

spark plug and try again.

Cold Weather Operation

If the ATV is used year-round, check the oil level frequently. A rising

oil level could indicate the accumulation of contaminates such as water

or excess fuel in the bottom of the oil tank. Water in the bottom of the

tank can lead to engine damage and must be drained. Water

accumulation increases as outside temperature decreases.

See your Polaris dealer for engine heater kits, which provide quicker

warm-ups and easier starting in colder weather.

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OPERATION

Hauling Cargo

2/3

1/3

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.

Cargo weight should be evenly distributed (1/3 on the front rack and

2/3 on the rear rack) and mounted as low as possible. When operating

over rough or hilly terrain, reduce speed and cargo weight to maintain

stable driving conditions. Do not obstruct the headlight beam with

cargo.

Belt Life

Use low forward gear when hauling or towing heavy cargo to extend

belt life.

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OPERATION

Hauling Cargo

WARNING

Hauling cargo improperly can alter vehicle handling and may

cause loss of control or brake instability and result in serious injury

or death. Always follow these precautions when hauling cargo:

S REDUCE SPEED AND ALLOW GREATER DISTANCES FOR

BRAKING WHEN HAULING CARGO.

S CARGO WEIGHT DISTRIBUTION should be 1/3 on the front

rack and 2/3 on the rear rack. When operating over rough or

hilly terrain, reduce speed and cargo to maintain stable driving

conditions. Carrying loads on one rack only increases the

possibility of vehicle overturn.

S CARRY LOADS AS LOW ON THE RACKS AS POSSIBLE.

Carrying loads high on the racks raises the center of gravity of

the vehicle and creates a less stable operating condition.

S SECURE ALL LOADS BEFORE OPERATING. Unsecured

loads can create unstable operating conditions, which could

result in loss of control of the vehicle.

S OPERATE ONLY WITH STABLE AND SAFELY ARRANGED

LOADS. When handling off-centered loads that cannot be

centered, securely fasten the load and operate with extra

caution. Always attach the tow load to the hitch point

designated for your vehicle.

S HEAVY LOADS CAN CAUSE BRAKING AND CONTROL

PROBLEMS. Use extreme caution when applying brakes with

a loaded vehicle. Avoid terrain or situations that may require

backing downhill.

S USE EXTREME CAUTION when operating with loads that

extend over the rack sides. Stability and maneuverability may

be adversely affected, causing the vehicle to overturn.

S DO NOT BLOCK THE FRONT HEADLIGHT BEAM when

carrying loads on the front rack.

S DO NOT TRAVEL FASTER THAN THE RECOMMENDED

SPEEDS. Vehicle should never exceed 10 mph (16 kph) while

towing a load on a level grass surface. Vehicle speed should

never exceed 5 mph (8 kph) when towing loads in rough terrain,

while cornering, or while ascending or descending a hill.

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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 brake.

5. Slowly depress the throttle with your right thumb and begin

driving. Vehicle speed is controlled by the amount of throttle

opening.

6. Drive slowly. Practice maneuvering and using the throttle and

brakes on level surfaces.

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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 slightly. To turn, steer in

the direction of the turn, leaning your upper body to the inside of the

turn while supporting your weight on the outer footrest. This

technique alters the balance of traction between the rear wheels,

allowing the turn to be made smoothly. The same leaning technique

should be used for turning in reverse.

NOTE: Practice making turns at slow speeds before attempting to turn

at faster speeds.

WARNING

Turning at sharp angles or at excessive speeds can result in vehicle

overturn and lead to serious injury. Avoid turning at sharp angles.

Never turn at high speeds.

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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, sharp turns, which can cause skids.

3. Correct a skid by turning the handlebars in the direction of the skid

and shifting your body weight forward.

4. Driving with All Wheel Drive engaged can assist in controlling the

vehicle in slippery areas.

CAUTION

Severe damage to drive train may occur if the AWD is engaged

while the wheels are spinning. Always allow the rear wheels to

stop spinning before engaging the AWD.

WARNING

Failure to exercise care when operating on slippery surfaces can

result in loss of tire traction and cause loss of control, accident,

and serious injury or death.

Never apply the brakes during a skid. Do not operate on

excessively slippery surfaces. Always reduce speed and use

additional caution.

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OPERATION

Driving Safely

Traveling Uphill

25_ Maximum

Whenever traveling uphill, follow these precautions:

1. Always travel straight uphill.

2. Avoid steep hills (25_ maximum).

3. Keep both feet on the footrests.

4. Transfer your weight forward.

5. Proceed at a steady rate of speed and throttle opening.

6. Remain alert and be prepared to take emergency action. This may

include quick dismounting of the vehicle.

WARNING

Braking and handling are greatly affected when operating in hilly

terrain. Improper procedure could cause loss of control or

overturn and result in serious injury or death.

Avoid climbing steep hills (25_ maximum).

Use extreme caution when operating on hills, and follow proper

operating procedures outlined in the owner’s manual.

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OPERATION

Driving Safely

Sidehilling

WARNING

Improperly crossing hills or turning on hills can result in loss of

control or vehicle overturn, resulting in severe injury or death.

Avoid crossing the side of a hill when possible. Follow proper

procedures as outlined in the owner’s manual.

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 the

hill while keeping your feet on the footrests.

3. Steer slightly into the hill to maintain vehicle directions.

NOTE: If the vehicle begins to tip, quickly turn the front wheel

downhill, if possible, or dismount on the uphill side immediately!

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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 in the event

loss of normal service brakes occurs.

WARNING

Excessive speed can cause loss of control and lead to serious

injury or death. Always operate slowly when traveling downhill.

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OPERATION

Driving Safely

Turning Around on a Hill

WARNING

Improper hill climbing procedures could cause loss of control or

overturn and result in serious injury or death.

Avoid climbing steep hills (25_ maximum).

Use extreme caution when operating on hills, and follow proper

operating procedures outlined in the owner’s manual.

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 transmission in forward and shut off the engine.

3. Dismount on the uphill side of the vehicle, or on the left if the

vehicle is pointing straight uphill.

4. Staying uphill of the vehicle, turn the handlebars full left.

5. While holding the service brake, release the parking brake lock and

slowly allow the vehicle to roll around to your right until it’s

pointing across the hill or slightly downward.

6. Lock the parking brake and remount the vehicle from the uphill

side, keeping body weight uphill.

7. Restart the engine with the transmission still in forward.

8. Release the parking brake and proceed slowly, controlling speed

with the service brake, until the vehicle is on more level ground.

8’

Uphill

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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 banks have gradual inclines.

3. Proceed slowly, avoiding rocks and obstacles if possible.

4. After crossing, dry the brakes by applying light pressure to the

lever until braking action is normal.

After running the vehicle in water, it’s critical to have it serviced as

outlined in the maintenance chart. See page 69. The following areas

need special attention: engine oil, transmission oil, front and rear

gearcases, and all grease fittings.

CAUTION

Major engine damage can result if the vehicle is not thoroughly

inspected after operation in water. Perform the services outlined in

the maintenance chart.

If your vehicle becomes immersed or is operated in water that

exceeds the footrest level, take it to your dealer for service before

starting the engine.

NOTE: Avoid operating the vehicle through deep or fast-flowing

water. If you cannot avoid water that exceeds the recommended

maximum depth, go slowly, balance your weight carefully, avoid

sudden movements, and maintain a slow and steady forward motion.

Do not make sudden turns or stops, and do not make sudden throttle

changes.

If your vehicle becomes immersed, and it’s impossible to take it to a

dealer before starting it, follow the steps described on page 102. Have

the vehicle serviced by your dealer at the first opportunity.

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OPERATION

Driving Safely

Driving Over Obstacles

Be alert! Look ahead and learn to read the terrain you’re traveling on.

Be constantly alert for hazards such as logs, rocks and low hanging

branches.

WARNING

Severe injury or death can result if your vehicle comes in contact

with a hidden obstacle. Not all obstacles are immediately visible.

Travel with caution in unfamiliar terrain.

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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.

WARNING

Failure to use caution when operating in reverse can result in

serious injury or death. Before shifting into reverse, always check

for obstacles or people behind the vehicle. When it’s safe to

proceed, back slowly.

Do not use the override switch unless additional power is required

for vehicle movement. Use with caution.

Avoid backing on inclines, and avoid turning at sharp angles.

NOTE: Your Polaris ATV is equipped with a reverse speed limiter.

The override button should be used with caution as rearward vehicle

speed is greatly increased. Do not operate at wide open throttle. Open

the throttle just enough to maintain a desired speed.

CAUTION

Excessive throttle operation while in the speed limit mode may

cause fuel to build in the exhaust, resulting in engine popping

and/or engine damage.

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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 as shown in the

illustration.

5. Shut off the fuel supply.

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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 device or

element of design incorporated into any new vehicle for the purpose of

noise control prior to its sale or delivery to the ultimate purchaser or

while it is in use or

(2) the use of the vehicle after such device or element of design has

been removed or rendered inoperative by any person.

ACTS PRESUMED TO CONSTITUTE TAMPERING INCLUDE

BUT ARE NOT LIMITED TO THE FOLLOWING:

1. Removal, alteration or the puncturing of the muffler or any engine

component that conducts removal of engine exhaust gases.

2. Removal, alteration or the puncturing of any part of the engine air

induction system.

3. Replacement of any vehicle parts with parts not in compliance with

federal regulations.

4. Lack of proper maintenance.

CAUTION

Exhaust system components are very hot during and after use of

the vehicle. Hot components can cause serious burns and fire.

Do not touch hot exhaust system components. Use caution when

traveling through tall grass, especially dry grass.

USFS Approved Spark Arrestor

Your Polaris ATV has a muffler that was tested and approved in

accordance with the USFS Forest Service Standard 5100-1A.

Exhaust Emission Control System

The exhaust emission control system is composed of efficient

carburetor settings with an optimum ignition system. Idle speed can be

adjusted with the throttle stop screw. The carburetor must be

maintained at Polaris specifications to achieve optimal performance.

Crankcase Emission Control System

This engine is equipped with a closed crankcase system. It allows

blow-by gases back to the combustion chamber using the intake

system. It does not allow the blow-by gases to enter the atmosphere.

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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’s programmable service interval

mode to help determine when maintenance service is due. See page 49

for instructions.

Maintenance intervals are based upon average riding conditions and an

average vehicle speed of approximately 10 miles per hour. Vehicles

subjected to severe use, such as operation in wet or dusty areas, should

be inspected and serviced more frequently.

Inspect, clean, lubricate, adjust and replace parts as necessary. When

inspection reveals the need for replacement parts, use genuine Polaris

parts available from your Polaris dealer.

NOTE: Service and adjustments are critical. If you’re not familiar

with safe service and adjustment procedures, have a qualified dealer

perform these operations.

Maintenance Chart Key

Perform these operations more often under severe use, such as in

dirty or wet conditions, to purge water or dirt contamination from

grease fittings and other critical components.

Emission Control System Service (California - 4-Cycle)

Dealer service item.

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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.

WARNING

Improperly performing the procedures marked with a J could result

in component failure and lead to serious injury or death. Have an

authorized Polaris dealer perform these services.

Item

Hours/

Miles

Frequency Remarks

Brake System

Auxiliary Brake

Tires

Pre-Ride Pre-Ride

Inspect

Wheels

Frame nuts, bolts,

fasteners

Air filter,

Pre-cleaner

Pre-Ride Pre-Ride

Inspect; clean

Coolant level

Pre-Ride Pre-Ride

Replace coolant every two

years

Fuel tank and

engine oil

Fill to proper levels

Throttle

Lights

Pre-Ride Pre-Ride

Check operation

Engine stop switch Pre-Ride Pre-Ride

Steering Pre-Ride Pre-Ride

Check operation

Check for free operation

" More often under severe use, such as dirty or wet conditions

L Emission Control System Service (California)

J Dealer service item

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MAINTENANCE AND LUBRICATION

Periodic Maintenance Schedule

Item

Hours/

Miles

Frequency Remarks

Air box sediment

tube

Pre-Ride Pre-Ride

Drain deposits whenever

visible

Headlamp

Check operation daily; ap-

ply Polaris dielectric grease

to connector when replaced

Tail lamp/brake

lamp

Pre-Ride Pre-Ride

Check operation daily; ap-

ply Polaris dielectric grease

to socket when replaced

Air filter,

main element

Weekly

Inspect; replace as needed

Transmission oil

level

20 hrs

Monthly

Inspect monthly; change

annually

Battery

Check terminals; clean;

check fluid level if applica-

ble

Engine breather

filter

20 hrs

Monthly

Inspect; replace annually

and as needed

Brake pad wear

10 hrs

Monthly

Inspect periodically

Front and rear

gearcase oil

100 hrs

Check monthly; change

annually

General lubrication 50 hrs

3 months

Lubricate all fittings, pivots,

cables, etc.

Engine oil level/oil

change

100 hrs / 6 months

1000

miles

Check level daily; break-in

service at one month;

change oil more often in

cold weather

Oil Filter

100 hrs./ 6 months

1000 mi.

Replace with oil change

Engine breather

hose

100 hrs. 6 months

Inspect

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MAINTENANCE AND LUBRICATION

Periodic Maintenance Schedule

WARNING

Improperly performing the procedures marked with a J could result

in component failure and lead to serious injury or death. Have an

authorized Polaris dealer perform these services.

Item

Hours/

Miles

Frequency Remarks

Carburetor float

bowl

50 hrs.

6 months

Drain bowl periodically and

prior to storage

Throttle Cable/ETC 50 hrs.

Switch

Inspect; adjust; lubricate;

replace if necessary

Choke (enricher)

cable

50 hrs.

Inspect; adjust; lubricate;

replace if necessary

Coolant strength

100 hrs. 6 months

Inspect strength seasonal-

ly; pressure test system

annually

Drive belt

50 hrs.

6 months

Inspect; replace as needed

Inspect daily; lubricate

Steering

Front suspension

Inspect; lubricate; tighten

fasteners

Rear suspension

Drive chain(s)

50 hrs.

6 months

Inspect; tighten fasteners

Inspect daily; adjust and lu-

bricate if needed

Spark plug

100 hrs. 12 months Inspect; replace as needed

" More often under severe use, such as dirty or wet conditions

L Emission Control System Service (California)

J Dealer service item

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MAINTENANCE AND LUBRICATION

Periodic Maintenance Schedule

Item

Hours/

Miles

Frequency Remarks

Rear axle

50 hrs.

6 months Inspect bearings; lube

Ignition Timing

100 hrs. 12 months Inspect; adjust as needed

Fuel system

100

hours

12 months Check for leaks at tank

cap, lines, fuel valve, filter,

pump and carburetor; re-

place lines every two years

Fuel filter

Radiator

100 hrs. 12 months Replace annually

100 hrs. 12 months Inspect; clean external sur-

face

Cooling system

hoses

100 hrs. 12 months Inspect

Spark arrestor

100 hrs. 12 months Clean out

Clutches (drive and 100 hrs. 12 months Inspect; clean

driven)

Engine mounts

Brake fluid

100 hrs. 12 months Inspect

200 hrs. 24 months Change every two years

300 hrs. 36 months Inspect; replace as needed

Front wheel bear-

ings

Idle speed

As required Adjust

Toe adjustment

As required Periodic inspection; adjust

when parts are replaced

Headlight aim

As required Adjust as needed

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MAINTENANCE AND LUBRICATION

Periodic Maintenance Record

Use the following chart to record periodic maintenance.

Maintenance

Interval

Performed

Servicing Servicing

Remarks

Date

Dealer

or Person

10 hrs.

20 hrs.

50 hrs.

100 hrs.

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- NOTES -

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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 under severe use, such as wet or dusty conditions

L Polaris Premium All Season Grease or grease conforming to NLGI

No. 2, such as Conoco Superlube M or Mobilegrease Special

Use Polaris Premium U-Joint Lube every 500 miles, before long

periods of storage, or after pressure washing or submerging.

Item

Lube

Method

Frequency

Engine OIl

Polaris Premium 4 Add to proper level on dip-

Check level daily.

Synthetic 0W40

stick.

Brake Fluid

DOT 3 Only

Maintain level between fill

lines. See page 39.

As required; change

every two years or

200 hours

Transmission Polaris Premium

See page 83 (400/500)

or page 85 (600/700).

Check every 6

Oil (Fig. 1)

Synthetic Gear

case Lube

months/1000 miles.

Change annually or

at 100 hours

Front Gear-

case Oil

(Fig. 2)

Premium Drive

Hub Fluid

See page 84 (400/500)

or page 86 (600/700).

Change annually or

at 100 hours

Rear Gear-

case Oil

(Fig. 3)

Premium Synthet- See page 87 (600/700).

ic Gearcase Lube

Change annually or

at 100 hours

(or GL5 80-90

weight gear lube)

Front Prop

Shaft Yoke

(Fig. 4)

FGrease

Grease fittings (3 pumps

maximum)

Every 3 months or

50 hours

Front Drive

Axle (U Joint)

(Fig. 5)

FGrease

Locate grease fitting and

grease with grease gun.

Every 3 months or

50 hours

Ball Joint

(Fig. 6)

Locate fitting on back side of Every 3 months or

struts and grease with

grease gun.

"LGrease

50 hours

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MAINTENANCE AND LUBRICATION

Lubrication Guide

(Fig. 1)

(Fig. 2)

(Fig. 3)

(Fig. 4)

(Fig. 6)

(Fig. 5)

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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 and protection. NOTE: See page 121 for the

part numbers of Polaris products.

Premium 4 possesses unsurpassed film strength over the widest

possible temperature range. It resists viscosity and frictional

breakdown in ambient temperatures from -40° F. to 120° F. (-40 to

+49° C.) Its exceptional frictional properties result in more efficient

operation, more power output and lower fuel consumption.

Although Polaris Premium 4 is the only oil recommended for use in

this engine, use of any API certified SH oil is allowable as long as it’s

0W-40. Oil may need to be changed more frequently if Polaris

Premium 4 is not used. Follow the manufacturer’s recommendations

for ambient temperature operation.

CAUTION

Mixing brands or using a non-recommended oil may cause

serious engine damage. We recommend the use of Polaris

Premium 4 synthetic Oil or another 0W-40 API certified SH oil.

Never substitute or mix oil brands.

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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 your

dipstick is equipped with a

lever lock (2), lift the lock to

remove the dipstick.

4. Reinstall the dipstick

completely, but do not lock it

(if equipped). The dipstick must

be screwed completely in to keep

the angle and depth of the stick

consistent.

ADD 8 OZ

SAFE

5. Remove the dipstick and

check the oil level. Maintain

the oil level in the normal or

safe range (3), depending on

the style of dipstick in your

model. Do not overfill.

ADD 8 OZ.

NORMAL

FULL

6. After reinstalling the

dipstick, be sure to seat

the lever lock (if

equipped).

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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 service. Severe use

includes continuous duty in dusty or wet conditions and cold weather

riding. NOTE: Severe use cold weather riding is all riding below 10°

F., and riding between 10° F and 30° F when most trips are slow speed

and less than five miles. Be sure to change the oil filter whenever

changing the oil.

Oil Change (400/500)

1. Position the vehicle on a level surface. Clean the area around the

drain plug at the bottom of the oil tank and the bottom of the

engine.

2. Run the engine for two to three minutes, then turn it off.

3. Place a drain pan beneath the oil tank and remove the drain plug

(1). Allow the oil to drain completely.

4. Install a new sealing washer (2) on the oil drain plug. NOTE:

The sealing surfaces on the drain plug and the oil tank should be

clean and free of burrs, nicks or scratches.

5. Reinstall the drain plug

and torque to 14-17 ft.

lbs. (19-23 Nm)

6. Disconnect the lower oil

delivery hose and remove

the screen fitting (3) from

the oil tank. Clean and

reinstall the fitting,

torquing to 25 ft. lbs.

Reattach the oil line.

NOTE: The fitting

threads must be sealed

with Loctitet PST 505 or

PTFE seal tape. The

fitting must also line up with

the mark (4) on the rear side of the oil tank.

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MAINTENANCE AND LUBRICATION

Oil Change (400/500)

7. Place shop towels beneath the oil filter. Using an oil filter wrench,

turn the filter (1) counterclockwise and remove.

8. Lubricate the gasket on the new filter with a film of new engine

oil. Check to make sure the gasket is in good condition. Also

make sure the gasket from the old filter is not still on the engine.

9. Install the new filter and tighten by hand 1/2 to 3/4 turn after

gasket contacts the engine.

10. Approximately one cup of

engine oil will remain in the

crankcase. To drain, remove

the drain plug on the lower

right side of the crankcase.

NOTE: The sealing

surfaces on the drain plug

and crankcase should be

clean and free of burrs, nicks

or scratches.

11. After draining, reinstall the

drain plug.

CAUTION

Loss of oil pump prime could result in engine damage. It’s

extremely important to drain, refill and start the engine in an

expedient manner. Do not allow the engine to sit without oil for

extended periods.

12. Remove the dipstick (2) and add two quarts (1.9 l) of the

recommended oil. Reinstall the dipstick. NOTE: If the sump is

not drained, add about 1 3/4 quarts initially.

13. Place the gear selector in neutral and set the parking brake.

14. Start the engine and let it idle for one to two minutes. Stop the

engine and inspect for leaks.

15. Recheck the oil level on the dipstick and add oil as necessary to

bring it to the recommended level on the dipstick.

16. Dispose of used filter and oil properly.

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MAINTENANCE AND LUBRICATION

Oil Change (600/700)

1. Place the vehicle on a level surface.

2. Run the engine for two to three minutes until warm. Stop the

engine.

3. Clean the area around the drain plug.

4. Place a drain pan beneath engine crankcase and remove the drain

plug.

CAUTION

Hot oil can cause serious burns. Do not allow hot oil to touch skin.

5. Allow the oil to drain completely.

6. Replace the sealing washer on the drain plug. NOTE: The sealing

surfaces on drain plug and crankcase should be clean and free of

burrs, nicks or scratches.

7. Reinstall the drain plug and torque to 20 ft. lbs. (27 Nm).

8. Place shop towels beneath the oil filter. Using an oil filter wrench,

turn the filter counterclockwise to remove.

9. Using a clean dry cloth, clean the filter sealing surface on the

crankcase.

10. Lubricate the o-ring on the new filter with a film of fresh engine

oil. Check to make sure the o-ring is in good condition.

11. Install the new filter and turn by hand until the filter gasket

contacts the sealing surface, then turn and additional 1/2 turn.

12. Remove the dipstick and fill the sump with two quarts (1.9 l) of

recommended oil.

13. Place the gear selector in PARK and set the parking brake.

14. Start the engine and let it idle for one to two minutes. Stop the

engine and inspect for leaks.

15. Re-check the oil level on the dipstick and add oil as necessary to

bring the level to the upper mark on the dipstick.

16. Dispose of used filter and oil properly.

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MAINTENANCE AND LUBRICATION

Transmission Oil (400/500)

The transmission oil level should be checked every six months or 1000

miles (1600 km), whichever comes first. Transmission oil should be

changed annually. We recommend the use of Polaris Premium

Synthetic Gearcase Lubricant. See page 121 for the part numbers of

Polaris products.

Oil Check

On the Sportsman 400 and 500, the transmission oil dipstick (1) is

located near the rear brake disc on the right side of the ATV.

1. Position the ATV on a level

surface. Remove the fill plug

dipstick and wipe it clean.

2. Reinstall the dipstick

completely, then

remove it and check the

level. Add the

recommended oil as needed

to bring the level into the

safe operating range (2).

Oil Change

1. Remove the fill plug/dipstick.

2. Remove the transmission

drain plug (3). It’s

located on the

bottom of the

gearcase.

3. Drain the oil into a

drain pan and

dispose of properly.

4. Clean and reinstall the drain plug.

5. Add 32 oz. (948 ml) of the recommended transmission oil to bring

the level to the full mark on the fill plug/dipstick. Maintain the oil

level in the safe range. NOTE: See page 121 for the part numbers

of Polaris products.

6. Reinstall the fill plug/dipstick and check for leaks.

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MAINTENANCE AND LUBRICATION

Front Gearcase Oil (400/500)

The front gearcase lubricant level should be checked every six months

or 1000 miles (1600 km), whichever comes first. Front gearcase oil

should be changed annually. Use Polaris Premium Synthetic Gearcase

Lube (or GL5 80-90 weight gear lube). See page 121 for the part

numbers of Polaris products.

Oil Check

1. Position the ATV on a level surface.

2. Remove the fill plug (1) and view the

lubricant level. Lubricant should be

kept level with the bottom of the fill

plug threads.

3. Add the recommended lubricant as

needed to bring the oil to the proper

level.

Oil Change

1. Position the vehicle on a level surface and remove the fill plug.

2. Place a drain pan beneath the gearcase, remove the gearcase drain

plug and drain the oil.

3. Clean and reinstall the drain plug. Torque to 14 ft. lbs. (19 Nm).

4. Add 4 ounces (120 ml) of the recommended gearcase oil.

5. Reinstall the fill plug and check for leaks.

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MAINTENANCE AND LUBRICATION

Transmission Oil (600/700)

The transmission oil level should be checked every six months or 1000

miles (1600 km), whichever comes first. Transmission oil should be

changed annually. We recommend the use of Polaris Premium

Synthetic Gearcase Lubricant. See page 121 for the part numbers of

Polaris products.

On the Sportsman 600 and 700, the transmission oil fill plug (1) is

located on the right side of the ATV behind the footwell.

Oil Check

1. To access the fill plug, remove

the four screws on the footwell

and gently pull outward to

remove the footwell.

2. Remove the fill plug and check

the oil level. The oil should be

maintained 1 5/8” from the top

of the fill plug hole.

Oil Change

1. Remove the four screws on the

1 5/8”

footwell and gently pull outward to

remove the footwell.

2. Remove the transmission drain plug

(2), which is located on the bottom

left-hand side. Drain the oil into a

drain pan and dispose of properly.

3. Clean and reinstall the drain plug.

Torque to 14 ft. lbs. (19 Nm).

4. Remove the fill plug and add 13.5 oz.

(399 ml) of the recommended

transmission oil to bring the level to

the proper level (1 5/8” from the top

of the fill plug hole).

5. Replace the fill plug and check for

leaks.

6. Reinstall the footwell and screws.

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MAINTENANCE AND LUBRICATION

Front Gearcase Oil (600/700)

The front gearcase lubricant level should be checked every six months

or 1000 miles (1600 km), whichever comes first. Front gearcase oil

should be changed annually. We recommend the use of Polaris

Premium Hub Drive Fluid. See page 121 for the part numbers of Polaris

products.

Oil Check

1. Position the ATV on a level surface.

2. Remove the fill plug (1) and view the

oil level. Maintain the oil level even

with the bottom of the fill plug hole.

3. Add the recommended gearcase oil as

needed.

Oil Change

1. Position the vehicle on a level surface

and remove the fill plug.

2. Place a drain pan beneath the gearcase, remove the gearcase drain

plug located on the bottom right-hand side, and drain the oil.

3. Clean and reinstall the drain plug. Torque to 14 ft. lbs. (19 Nm).

4. Add 5 ounces (150 ml) of Polaris Premium Hub Drive Fluid.

5. Reinstall the fill plug and check for leaks.

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MAINTENANCE AND LUBRICATION

Rear Gearcase Oil (600/700)

The rear gearcase lubricant level should be checked every six months

or 1000 miles (1600 km), whichever comes first. Rear gearcase oil

should be changed annually. Use Polaris Premium Synthetic Gearcase

Lube (or GL5 80-90 weight gear lube). NOTE: See page 121 for the

part numbers of Polaris products.

Oil Check

1. Position the ATV on a level surface.

2. Remove the fill plug and inspect the oil level through the fill plug

hole (1). Maintain the oil level even with the bottom of the fill plug

hole.

3. Add the recommended gearcase oil as needed.

Oil Change

1. Place a drain pan beneath the drain

and remove the drain plug (2).

Catch and discard used oil properly.

2. Clean and reinstall the drain plug

with a new sealing washer. Torque

to 14 ft. lbs. (19 Nm).

3. Remove the fill plug and add 5

ounces (150 ml) of the recommended

gearcase oil.

4. Inspect the oil level, which should be

maintained level with the bottom of the fill plug hole.

5. Reinstall the fill plug. Torque to 14 ft. lbs. (19 Nm) and check for

leaks.

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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 bottle (when the fluid is

cool).

The engine coolant level is controlled or maintained by the recovery

system. The recovery system components are the recovery bottle,

radiator filler neck, radiator pressure cap and connecting hose.

As coolant operating temperature increases, the expanding (heated)

excess coolant is forced out of the radiator, past the pressure cap, and

into the recovery bottle. As engine coolant temperature decreases, the

contracting (cooled) coolant is drawn back up from the tank, past the

pressure cap, and into the radiator.

NOTE: Some coolant level drop on new machines is normal, as the

system is purging itself of trapped air. Observe coolant levels and

maintain as recommended by adding coolant to the recovery bottle.

Polaris recommends the use of Polaris Premium 60/40

anti-freeze/coolant or a 50/50 mixture of high quality aluminum

compatible anti-freeze/coolant and distilled water. See page 121 for the

part numbers of Polaris products.

NOTE: Polaris Premium 60/40 is already premixed and ready to use.

Do not dilute with water.

NOTE: Always follow the manufacturer’s mixing recommendations

for the freeze protection required in your area.

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MAINTENANCE AND LUBRICATION

Engine Cooling System

WARNING

Escaping steam can cause severe burns. Never remove the

pressure cap while the engine is warm or hot. Always allow the

engine to cool before removing the pressure cap.

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 necessary.

1. Using the tool provided, remove

the four screws securing the front rack (1). Remove the front cover

(2) by placing your fingers under the front of the cover and pulling

upward.

2. Remove the pressure cap.

3. Using a funnel, slowly add coolant as necessary through the

radiator filler neck.

4. Replace the pressure cap and secure the front cover and rack.

NOTE: Use of a non-standard pressure cap will not allow the

recovery system to function properly. Contact your dealer for the

correct replacement part.

NOTE: To ensure that the coolant maintains its ability to protect the

engine, we recommend that the system be completely drained every

two years and a fresh mixture of antifreeze and water added. Polaris

recommends the use of Polaris Premium 60/40 anti-freeze/coolant or a

50/50 mixture of high quality aluminum compatible anti-freeze/coolant

and distilled water. Polaris Premium 60/40 is already premixed and

ready to use. Do not dilute with water. See page 121 for the part

numbers of Polaris products.

NOTE: Always follow the manufacturer’s mixing recommendations

for the freeze protection required in your area.

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MAINTENANCE AND LUBRICATION

Front Brake

WARNING

After opening a bottle of brake fluid, always discard any

unused portion. Never store or use a partial bottle. Brake

fluid is hygroscopic, meaning it rapidly absorbs moisture from

the air. The moisture causes the boiling temperature of the

brake fluid to drop, which can lead to early brake fade and the

possibility of accident or severe injury.

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 brakes are used heavily

under normal operation.

1. Always keep brake fluid at an adequate level (see page 39).

NOTE: Under normal functioning the diaphragm extends into the

reservoir as fluid level drops. If the fluid level is low and the

diaphragm is not extended, a leak is likely and the diaphragm

should be replaced. Always fill the reservoir as needed whenever

the cover is loosened or removed to ensure proper diaphragm

operation. Use Polaris DOT 3 brake fluid (see page 121).

2. Check the brake system for fluid leaks.

3. Check the brakes for excessive

travel or spongy feel.

4. Check the friction pads for wear,

damage and looseness.

5. Check the security and surface

condition of the disc.

NOTE: Pads should be changed when worn

to 3/64″ (.1 cm), or about the thickness of a

U.S. dime.

3/64″ (.1 cm)

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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 worn to

3/64″ (.1 cm), which is about the thickness

of a U.S. dime.

Inspect the brake disc spline and pad wear

surface for excessive wear.

3/64″ (.1 cm)

Auxiliary Brake

Your auxiliary brake is intended to be used as a backup for the main

brake system. Should the main system fail, the rear brake can be

activated by depressing the foot pedal on the inside of the right

footrest. The hydraulic auxiliary brake system will not require

adjustment.

NOTE: Since this is a rear brake only, it will not be as effective as the

all wheel system.

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MAINTENANCE AND LUBRICATION

Toe Alignment

WARNING

Severe injury or death can result from improper toe alignment and

adjustment. Do not attempt to adjust tie rod alignment. All tie rod

adjustments should be performed by an authorized Polaris dealer.

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 handlebars are

straight. The frog should

always point straight back

from the steering post.

2. Place stands (1) in front of

the vehicle, perpendicular to

the rear tires. See

illustration.

3. Tie an elastic string around

the stands, making sure the

string just touches the side

surface of the rear tires on

each side of the vehicle and

goes around the stands in

front of the vehicle (2).

4. Measure the distance from

the string to the rim at the

front and rear of the front

rim (3). Rear measurement should be 1/16″ - 1/8″ (.2 to .3 cm)

more than the front measurement.

NOTE: If you discover improper alignment, see your Polaris dealer

for service.

Steering Assembly

The steering assembly of the ATV should be checked periodically for

loose nuts and bolts. If loose nuts and bolts are found, see your Polaris

dealer for service before operating the vehicle.

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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

Step 2

panel near the rear cab. With

a quick and firm motion, pull

the panel forward and outward

to disengage the two rear tabs.

3. Place your hand on top of the

side panel behind the fuel

tank. With a quick and firm

motion, push down on the side

panel to disengage the top rear

two tabs. Then pull up on the

side panel to disengage the

front upper and lower tabs.

Step 3

4. To reinstall the side panel,

align the panel tabs with the

slots on the front cab. Push

the panel upward and forward

until the tabs lock. Bend the

rear of the side panel and

insert the two tabs into the rear

cab.

Step 4

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MAINTENANCE AND LUBRICATION

WARNING

Operating your ATV with worn tires, improperly inflated tires,

non-standard tires or improperly installed tires will affect vehicle

handling and could cause an accident resulting in serious injury

or death.

Maintain proper tire pressure as described on the decal on your

ATV and in the owner’s manual.

Always use original equipment size and type when replacing

tires.

Make sure the wheels are installed properly.

Always replace tires when the tread depth measures 1/8″ (.3 cm)

or less.

Tire Tread Depth

Always replace tires when tread

depth is worn to 1/8″ (.3 cm) or less.

1/8I (.3 cm)

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 the side of the vehicle by placing a suitable stand under the

footrest frame.

4. Remove the wheel nuts and remove the wheel.

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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 nuts and finger

tighten.

4. Lower the vehicle to the ground.

5. Torque the wheel nuts according to the wheel nut torque

specifications chart.

NOTE: All nuts that have a cotter pin installed must be serviced by an

authorized Polaris dealer.

Wheel Nut Torque Specifications

Check the wheel nut torques occasionally and when they’ve been

loosened for maintenance service.

Bolt Size

Front 3/8″

Rear 3/8″

Sportsman 400/500

20 ft. lbs. (27 Nm)

Sportsman 600/700

30 ft. lbs. (41 Nm)

Front Wheel Hub Tightening

Front wheel bearing tightness and spindle nut retention are critical

component operations. All service must be performed by your

authorized Polaris dealer.

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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 rinse and

let dry.

4. Reinstall the pre-filter over the

main filter. (Replace the main

filter if needed.)

5. Reinstall the filter into the air box and tighten the clamp. Do not

over tighten the clamp, as filter damage could occur.

6. Reinstall the air box cover and the seat.

Breather Filter/Hose

1. To access the breather filter (3), remove the left side panel as

outlined on page 93. The breather filter is on the hose that runs

between the engine and air box.

2. Remove the clamps and pull the filter out of the hoses.

NOTE: It’s not necessary to remove the lower hose from the

engine.

3. Inspect the filter for debris. Blow gently through the filter in the

direction of the arrow to check for clogging. Replace if needed.

4. Check the hoses for cracks, deterioration, abrasion, or leaks.

Replace as needed.

5. Reinstall the filter and secure the clamps. NOTE: The filter is

effective with the arrow pointing in either direction.

CAUTION

Operation of your vehicle without a breather filter can cause

engine damage. Always reinstall the breather filter after

removing for service.

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MAINTENANCE AND LUBRICATION

Lights

When servicing a halogen lamp, don’t touch the lamp with bare

fingers. Oil from your skin leaves a residue, causing a hot spot that

will shorten the life of the lamp.

WARNING

Poor lighting while driving can result in severe injury or death.

Headlight and taillight lenses become dirty during normal operation.

Wash the headlights frequently to maintain lighting quality.

Hot components can cause serious burns to skin. Do not service

the headlamps until they’ve cooled sufficiently.

Headlight Lamp 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 while depressing the tabs.

4. Remove the screw in the back of the headlight pod.

5. Lift the pod cover and disconnect the speedometer harnesses from

the speedometer. Unplug the indicator light harness and remove

the pod cover.

6. Unplug the headlamp from the wiring harness. Be sure to pull on

the connector, not on the wiring.

7. Remove the boot and locking collar from the back of the lamp

housing.

8. Grasp the base of the lamp and lift it out.

9. Reverse the previous steps to replace the lamp and reassemble the

pod. Apply dielectric grease to the light bulb socket before

installing the new bulb. Make sure the tab on the lamp locates

properly in the housing.

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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. Measure the distance from the floor to the center of the headlight

and make a mark on the wall at the same height.

3. Start the engine and turn the headlight switch to high beam.

4. Observe the headlight aim on the wall. The most intense part of

the headlight beam should be aimed two inches (5.1 cm) below the

mark placed on the wall. NOTE: Include rider weight on the seat

when measuring.

5. Adjust the beam to the desired position by turning the adjustment

knob either clockwise or counterclockwise.

Snap pins

into tabs

Position

Slip o-ring

over pin

knob in

slot and

Route plug

over handlebar

secure in

locking

tabs

Adjustment

Knob Stop

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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 while depressing the tabs.

4. Remove the screw in the back of the

headlight pod.

5. Lift the pod cover. Disconnect the

speedometer harnesses from the

speedometer. Unplug the indicator

light harness and remove the pod cover.

6. Unplug the headlamp from the wiring

harness.

7. Remove the o-ring (1) from the

headlight pivot pins.

8. Pull the headlight housing up to

release from the locking tabs.

9. Lift the adjusting knob up to remove

from the locking tabs.

10. Carefully pull the assembly up and

out of pod.

5 1/8″

(13 cm)

11. Reverse the steps to install the new housing and reassemble the

pod.

NOTE: The distance from the headlamp parting line to the end of the

adjustment knob stop is 5 1/8″ (13 cm). See illustration.

12. Adjust the headlight aim by turning the adjusting knob.

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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 harness assembly

into the headlight assembly. Turn the headlight harness

counterclockwise to secure the headlamp into place.

Taillight/Brakelight Lamp Replacement

If the taillight/brakelight does not work the lamp may need to be

replaced.

1. Remove the taillight lens

cover mounting screws (1).

Remove the lens cover (2) and

gasket and set aside for

reassembly.

2. Remove the lamp (3) and

replace it with a new lamp.

3. Test the taillight/brakelight to

see that it’s working.

4. Reinstall the gasket and lens cover.

100

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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).

CAUTION

Using non-recommended spark plugs can result in serious engine

damage. Always use Polaris-recommended spark plugs.

Spark plug condition is indicative of engine operation. The spark plug

firing end condition should be read after the engine has been warmed

up and the vehicle has been driven at higher speeds. Immediately

check the spark plug for correct color.

WARNING

A hot exhaust system and engine can cause serious burns. Wear

protective gloves when removing a spark plug for inspection.

1. Normal

The normal insulator tip is gray, tan or light brown. There will be few

combustion deposits. The electrodes are not burned or eroded. This

indicates the proper type and heat range for the engine and the service.

NOTE: The tip should not be white. A white insulator tip indicates

overheating, caused by use of an improper spark plug or incorrect

carburetion adjustments.

2. Wet Fouled

The wet fouled insulator tip is black. A damp oil film covers the firing

end. There may be a carbon layer over the entire nose. Generally, the

electrodes are not worn. General causes of fouling are excessive oil,

use of non-recommended oil, improper use of the choke, or incorrect

carburetion adjustments.

Spark Plug Removal and Replacement

1. Remove the spark plug cap.

2. Using the special wrench provided in the tool pouch, rotate the

spark plug counterclockwise to remove.

3. Reverse the procedure for spark plug installation. Torque to 18 ft.

lbs. (24 Nm).

101

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MAINTENANCE AND LUBRICATION

Vehicle Immersion

CAUTION

If your vehicle becomes immersed, major engine damage can

result if the machine is not thoroughly inspected. Take the vehicle

to your dealer before starting the engine.

If it’s impossible to take your ATV to a dealer before starting it, follow

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. Filter

replacement is required if water

intrusion is evident.

3. Turn the fuel valve off.

4. Remove the spark plug.

5. Loosen the carburetor drain screw (1).

6. Turn the engine over several times

using the electric start.

7. Dry the spark plug and reinstall, or replace it with a new plug.

8. Tighten the carburetor drain screw.

9. Turn the fuel valve on.

10. Attempt to start the engine. If necessary, repeat the drying

procedure.

11. Take the ATV to your dealer for service as soon as possible,

whether you succeed in starting it or not.

NOTE: If water has been ingested into the PVT, follow the procedure

on page 105 for drying out the PVT.

102

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MAINTENANCE AND LUBRICATION

Spark Arrestor

WARNING

Failure to heed the following warnings while servicing the spark

arrestor could result in serious injury or death.

Do not perform service on the spark arrestor while the system is

hot. Exhaust system temperatures can reach 1000° F. Allow

components to cool sufficiently before proceeding.

Remove any combustible materials from the area.

Wear eye protection.

Do not stand behind or in front of the vehicle while purging.

Never run the engine in an enclosed area. Exhaust contains

poisonous carbon monoxide gas.

Never go under the vehicle while it’s inclined.

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.

3. Purge carbon from the system by

momentarily revving the engine

several times.

4. If carbon is expelled, cover or plug the

exhaust outlet (2) and rap on the pipe around

the cleanout plug while revving the engine several more times.

5. If particles are still suspected to be in the muffler, elevate the rear

of the vehicle one foot higher than the front. Set the parking brake

and block the wheels. Make sure the vehicle is in neutral (or

PARK, if equipped) and repeat steps 3 and 4 until no more

particles are expelled when the engine is revved.

6. Stop the engine and allow the arrestor to cool. Reinstall the

arrestor plug and remove the outlet cover or plug.

103

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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 pinch applied to the

drive belt. Similarly, if the engine speed decreases, the amount of

centrifugal force decreases, reducing the amount of belt pinch.

On Polaris ATVs, the approximate gear ratio difference between high

and low range is 1:2.25. This difference in gearing affects the operation

of the PVT, especially at speeds less than 7 MPH (11 KPH), due to the

system’s dependence on engine speed.

For example, when operating at a ground speed of 3 MPH (5 KPH) in

low range, the engine speed would be around 3000 RPM. This is well

above the engagement speed of 1200 - 1400 RPM. However, in high

range at 3 MPH (5 KPH), the engine would be running at only 1500

RPM. Whenever operating this close to the engagement speed, the

engine may be running at a speed too low to provide the pinch needed

to prevent belt slip. Belt slip is responsible for creating the excessive

heat that destroys belts and causes outer clutch covers to fail.

By switching to low range while operating at low ground speeds, the

air temperature in the clutch cover is reduced by almost 160 degrees.

Reducing the temperature inside the clutch cover extends the life of the

PVT components (belt, cover, etc.).

When To Use Low Range vs. High Range

Following is a guideline for when to use low range and high range.

Low Range

S When basic operation is at speeds less than 7 MPH (11 KPH)

S For heavy pulling

S When operating in rough terrain (swamps, mountains, etc.) at low

ground speeds

High Range

S When basic operation is at speeds greater than 7 MPH (11 KPH)

S When operating at high ground speeds

104

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MAINTENANCE AND LUBRICATION

PVT System

WARNING

Failure to comply with the instructions in this warning can result

in severe injury or death.

Do not modify any component of the PVT system. Doing so may

reduce its strength so that a failure may occur at a high speed.

The PVT system has been precision balanced. Any modification

will cause the system to be out of balance, creating vibration and

additional loads on components.

The PVT system rotates at high speeds, creating large amounts

of force on clutch components. Extensive engineering and

testing has been conducted to ensure the safety of this product.

However, as the owner, you have the following responsibilities to

make sure this system remains safe:

Always follow all recommended maintenance procedures. See

your dealer as outlined in the owner’s manual.

This PVT system is intended for use on Polaris products only. Do

not install it in any other product.

Always make sure the PVT housing is securely in place during

operation.

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 and shift the transmission into neutral. Apply

varying throttle for 10-15 seconds to expel the moisture and air-dry

the belt and clutches. Do not hold the throttle wide open for more

than 10 seconds.

3. Allow the engine RPM to settle to idle speed, then shift the

transmission to the lowest available range.

4. Test for belt slippage. If the belt slips, repeat the process.

5. Take the vehicle to your dealer for service as soon as possible.

105

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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 with a solution of

one tablespoon baking soda and one cup water. Rinse well with tap

water and dry off with clean shop towels. Coat the terminals with

dielectric grease or petroleum jelly. Be careful not to allow cleaning

solution or tap water into the battery.

WARNING

Battery electrolyte is poisonous. It contains sulfuric acid. Serious

burns can result from contact with skin, eyes or clothing.

Antidote:

External: Flush with water.

Internal: Drink large quantities of water or milk. Follow with milk

of magnesia, beaten egg, or vegetable oil. Call physician

immediately.

Eyes: Flush with water for 15 minutes and get prompt medical

attention.

Batteries produce explosive gases. Keep sparks, flame,

cigarettes, etc. away. Ventilate when charging or using in an

enclosed space. Always shield eyes when working near batteries.

KEEP OUT OF REACH OF CHILDREN.

106

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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) battery cable next.

5. Lift the battery out of the ATV. Be careful not to tip a conventional

battery sideways, which could spill electrolyte.

CAUTION

If electrolyte spills, immediately wash it off with a solution of one

tablespoon baking soda and one cup water to prevent damage to

the vehicle.

Battery Installation

1. Set the battery in the battery holder.

2. With conventional batteries, install the battery vent tube (sealed

batteries do not have a vent tube). NOTE: The vent tube must be

free of obstructions and securely installed. If not, battery gases

could accumulate and cause an explosion. The tube should be

routed away from the frame and body to prevent corrosion. Avoid

skin contact with electrolyte, which can cause severe burns.

3. First connect and tighten the red (positive) cable.

4. Second connect and tighten the black (negative) cable.

5. Reinstall the battery cover and attach the hold-down strap.

6. Verify that cables are properly routed.

NOTE: When installing a new battery, make sure it’s fully charged

prior to its initial use. Using a new battery that has not been fully

charged can damage the battery and result in a shorter life. It can also

hinder vehicle performance.

107

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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 leads may need to be bent down so that the battery cover

can be installed.

Replenishing Battery Fluid (Conventional Battery)

A poorly maintained battery will

deteriorate rapidly. Check the battery

fluid level often. The fluid level should

be kept between the upper and lower

level marks (1).

To refill use only distilled water. Tap

water contains minerals that are harmful

to a battery.

WARNING

Improperly connecting or disconnecting battery cables can result

in an explosion and cause serious injury or death. When removing

the battery, always disconnect the negative (black) cable first.

When reinstalling the battery, always connect the negative (black)

cable last.

Battery Charging (Sealed Battery)

The following battery charging instructions apply only to the

installation of a YUASA activated, sealed battery. Read all

instructions before proceeding with the installation of this battery.

The YUASA activated, sealed battery is already filled with electrolyte

and has been sealed and fully charged at the factory. Do not ever pry

the sealing strip off or add any other fluid to this battery.

The single most important thing to maintaining a sealed battery is to

keep it fully charged. Since the battery is sealed and the sealing strip

cannot be removed, you must use a voltmeter or multimeter to measure

DC voltage.

108

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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 the battery.

NOTE: When using an automatic charger, refer to the charger

manufacturer’s instructions for recharging. When using a constant

current charger, use the following guidelines for recharging.

WARNING

An overheated battery could explode, causing severe injury or

death. Always watch charging times carefully. Stop charging if

the battery becomes very warm to the touch. Allow it to cool

before resuming charging.

NOTE: Always verify battery condition before and 1-2 hours after the

end of charging.

State of

Charge

Voltage

Action

Charge Time*

(Using constant current

charger @ standard amps

specified on top of battery)

100%

12.8-13.0 volts

12.5-12.8 volts

None, check at

3 mos. from date of

manufacture

None required

75%-100%

May need slight

charge, if no

charge given,

check in 3 months

3-6 hours

50%-75%

25%-50%

12.0-12.5 volts

11.5-12.0 volts

Needs Charge

5-11 hours

At least 13 hours,

verify state of charge

0%-25%

11.5 volts or less

Needs Charge

At least 20 hours

109

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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.

Cleaning and Storage

See page 121 for the part numbers of Polaris products.

Cleaning the ATV

Keeping your ATV clean will not only improve its appearance but it

can also extend the life of various components. With a few

precautions, your ATV can be cleaned much like an automobile.

Washing the ATV

The best and safest way to clean your ATV is with a garden hose and a

pail of mild soap and water. Use a professional type washing mitten,

cleaning the upper body first and the lower parts last. Rinse with water

frequently and dry with a chamois to prevent water spots. NOTE: If

warning and safety labels are damaged, contact your a Polaris dealer

for free replacement.

Polaris does not recommend the use of a high pressure type car wash

system for washing the ATV. If a high pressure system is used,

exercise extreme care to avoid water damage to the wheel bearings,

transmission seals, body panels, brakes and warning labels. NOTE:

Grease all zerk fittings immediately after washing, and allow the

vehicle to run for a while to evaporate any water that may have entered

the engine or exhaust system.

Waxing the ATV

Your ATV can be waxed with any non-abrasive automotive paste wax.

Avoid the use of harsh cleaners since they can scratch the body finish.

CAUTION

Certain products, including insect repellants and chemicals, will

damage plastic surfaces. Use caution when using these products

near plastic surfaces.

110

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MAINTENANCE AND LUBRICATION

Cleaning and Storage

Storage Tips

CAUTION

Starting the engine during the storage period will disturb the protective

film created by fogging and damage could occur. Never start the

engine during the storage period.

Clean the Exterior

Make necessary repairs and then 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 dish soap type cleaners only. High pressure washers may

force water past seals.

Stabilize the Fuel

Fill the fuel tank. Add Polaris Carbon Clean Fuel Treatment or Polaris

Fuel Stabilizer. Follow the instructions on the container for the

recommended amount. (Carbon clean will also reduce the possibility of

bacterial growth in the fuel system.) Allow 15-20 minutes of operation

for the stabilizer to disperse through the fuel in the tank and carburetor.

Turn the fuel valve off and drain the carburetor bowl.

Oil and Filter

Warm the engine and change the oil and filter.

Air Filter / Air Box

Inspect and clean or replace the pre-cleaner and air filter. Clean the air

box and drain the sediment tube.

Breather Filter

Inspect and clean or replace the breather filter.

Fluid Levels

Inspect the following fluid levels and change if necessary: front and

rear gearcases; transmission and brake fluid (change every two years or

as required if fluid looks dark or contaminated).

111

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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 of oil. NOTE: Do this carefully! If you miss

the plug hole, oil will drain from the spark plug cavity into the hole

at the front of the cylinder head, and appear to be an oil leak.

2. Reinstall the spark plug. Torque to 18 ft. lbs. (24 Nm).

3. Apply dielectric grease to the inside of the spark plug cap and install

the cap onto the plug.

4. Turn the engine over several times. Oil will be forced in and around

the piston rings and ring lands, coating the cylinder with a protective

film of fresh oil.

Alternative to Using Fogging Oil

If you choose not to use Polaris Fogging Oil, perform the following

procedure.

1. Treat the fuel system with Polaris Carbon Clean, following the

instructions on the can. Run the engine for several minutes so the

Carbon Clean reaches the carburetor. Turn the engine off.

2. Support the front end of the machine so the engine is level or tilted

slightly rearward.

3. Remove the spark plug. Rotate the piston to BDC and pour

approximately two ounces of recommended oil into the cylinder.

4. Reinstall the spark plug and torque to 18 ft. lbs. (24 Nm).

5. Apply dielectric grease to the inside of the spark plug cap and install

the cap onto the plug.

6. Turn the engine over several times to ensure coverage of piston

rings, cylinder walls and crankshaft bearings.

7. If Polaris fuel system additive is not used, fuel tank, fuel lines, and

carburetor should be completely drained of gasoline. To eliminate

any fuel remaining in the carburetor, run the engine until it stops.

Inspect and Lubricate

Inspect all cables and lubricate. Follow lubrication guidelines in the

Maintenance Section of the service or owner’s manual to completely

grease and lubricate the entire vehicle with Polaris Premium All

Season Grease.

112

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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. Charge the

battery at 1.4 amps or less until the specific gravity of each cell is

1.265 or greater. Store the battery in a cool, dry place.

Charge can be maintained easily by using Polaris Battery Tendert

charger (PN 2871076) or by charging about once a month to make up

for normal self-discharge. Battery Tendert can be left connected

during the storage period, and will automatically charge the battery if

the voltage drops below a pre-determined point. Check the fluid level

monthly.

Battery Maintenance (Sealed)

Remove the battery and recharge it as outlined on page 108. Store the

battery in a cool, dry place.

Engine Anti-Freeze

Test engine coolant strength and change if necessary. Coolant should

be replaced every two years.

Storage Area/Covers

Set the tire pressure and safely support the ATV with the tires 1-2” off

the ground. Be sure the storage area is well ventilated, and cover the

machine with a genuine Polaris ATV cover. NOTE: Do not use plastic

or coated materials. They do not allow enough ventilation to prevent

condensation, and may promote corrosion and oxidation.

Transporting the ATV

Follow these procedures when transporting the vehicle.

1. Turn off the engine and remove the key to prevent loss during

transporting.

2. Turn the fuel valve off and be sure the fuel cap, oil cap and seat are

installed securely.

3. Always tie the frame of the ATV to the transporting unit securely

with suitable straps or rope.

4. Always place the transmission in gear (or in PARK if equipped)

and lock the parking brake.

113

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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

dealer.

Handlebars

WARNING

Improper adjustment of the handlebars or incorrect torquing of

the adjuster block tightening bolts can cause limited steering or

loosening of the handlebars, resulting in loss of control and

possible serious personal injury or death. Follow the adjustment

procedures exactly, or see your Polaris dealer for service.

The handlebars can be adjusted for

rider preference.

1. Locate handlebar bolts (1) by

removing the upper headlight pod.

2. Loosen the four bolts.

3. Adjust the handlebar to the desired

height. Be sure the handlebars do not

contact the gas tank or any other part of

the machine when turned fully to the left or right.

4. Torque the front two bolts to 10-12 ft. lbs. (14-17 Nm), then torque

the rear two bolts. A gap of up to 1/8” will remain at the rear bolts.

114

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ADJUSTMENTS

Carburetor/Idle RPM

If the engine idle speed is not satisfactory, and

all other conditions are favorable, the carburetor

can be adjusted.

1. Warm up the engine by running the vehicle

for approximately five minutes.

2. Place the transmission in gear with the

parking brake applied.

3. Adjust the carburetor idle screw (1) either in

or out until the desired idle RPM is reached.

Turning the screw in (clockwise) will raise

RPM. Turning the screw out

(counterclockwise) will lower RPM.

IMPORTANT: Your Polaris ATV is calibrated at the factory for

optimal performance at altitudes ranging from zero to 6,000 feet (1800

m) and temperatures of +40 degrees F. (4 degrees C.) or higher. Above

6000 feet (1800 m) the engine air/fuel mixture becomes overly rich and

the engine loses approximately 3% of its power for each 1000-foot

(304.8 m) increase in elevation. Although this power cannot be

regained, adjustments to the carburetor and drive system can be made

to allow more efficient operation. Optional jets, available from your

Polaris dealer, are required for operation above 6,000 feet and

temperatures below +40 degrees F. (4 degrees C.)

NOTE: Continuous operation of the engine without proper jetting

when required can cause poor performance, overheating or engine

damage. See your Polaris dealer for more information about jetting the

ATV for conditions in your area.

115

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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 freeplay, be sure to flip the

throttle lever back and forth.

3. Tighten the locknut and slide the boots over the cable adjuster until

they touch at the midpoint of the adjuster.

116

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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 range or dis-

mount the ATV (after first applying the park brake) and

perform the K-turn as described on page 63.

Driving at low RPM or

low ground speed (at

Drive at a higher speed or use low range more frequently.

The use of low range is highly recommended for cooler

approximately 3-7 MPH). PVT operating temperatures and longer component life.

Insufficient warm-up of Warm the engine at least 5 minutes. With the transmission

ATVs exposed to low am- in neutral, advance the throttle to about 1/8 throttle in

bient temperatures.

short bursts, 5 to 7 times. The belt will become more flex-

ible and prevent belt burning.

Slow and easy clutch en- Use the throttle quickly and effectively for efficient enga-

gagement.

gement.

Towing/pushing at low

RPM/low ground speed.

Use low range only.

Utility use/plowing snow, Use low range only.

dirt, etc.

Stuck in mud or snow.

Shift the transmission to low range, and carefully use fast,

aggressive throttle application to engage clutch.

WARNING: Excessive throttle may cause loss of control

and vehicle overturn.

Climbing over large ob-

Shift the transmission to low range, and carefully use fast,

jects from a stopped posi- brief, aggressive throttle application to engage clutch.

tion.

WARNING: Excessive throttle may cause loss of control

and vehicle overturn.

Belt slippage from water

Shift the transmission to neutral. Using the throttle, vary

or snow ingestion into the the engine RPM from idle to full throttle. Repeat several

PVT system.

times as required. During this procedure, the throttle

should not be held at the full position for more than 10

seconds. Clutch seals should be inspected for damage if

repeated leaking occurs.

Clutch malfunction.

Contact your Polaris dealer for inspection of clutch com-

ponents.

Poor engine performance. Check for fouled plugs or foreign material in gas tank,

fuel lines, or carburetor. Contact your dealer for service.

117

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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

Low battery voltage

Reset the breaker

Recharge battery to 12.5 VDC

Check all connections and tighten

Loose battery connections

Loose solenoid connections

Engine Turns Over, Fails to Start

Possible Cause

Solution

Out of fuel

Turn fuel valve to reserve, refuel

Inspect and clean or replace

Drain the fuel system and refuel

Turn the fuel valve on

Clogged fuel valve or filter

Water is present in fuel

Fuel valve is turned off

Old or non-recommended fuel

Fouled or defective spark plug(s)

No spark to spark plug

Crankcase filled with water or fuel

Overuse of choke

Replace with new fuel

Inspect plug(s), replace if necessary

Inspect plug(s), verify stop switch is on

Immediately see your Polaris dealer

Inspect, clean and/or replace spark plugs

Replace the filter

Clogged fuel filter

Low battery voltage

Recharge battery to 12.5 VDC

See your Polaris dealer

Mechanical failure

Engine Pings or Knocks

Possible Cause

Solution

Poor quality or low octane fuel

Incorrect ignition timing

Replace with recommended fuel

See your Polaris dealer

Set gap to specs or replace plugs

Incorrect spark plug gap or heat range

118

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TROUBLESHOOTING

Engine Backfires

Possible Cause

Solution

Weak spark from spark plugs

Incorrect spark plug gap or heat range

Old or non-recommended fuel

Incorrectly installed spark plug wires

Incorrect ignition timing

Inspect, clean and/or replace spark plugs

Set gap to specs or replace plugs

Replace with new fuel

See your Polaris dealer

Mechanical failure

Engine Runs Irregularly, Stalls or Misfires

Possible Weak Spark Cause

Fouled or defective spark plugs

Worn or defective spark plug wires

Incorrect spark plug gap or heat range

Loose ignition connections

Water present in fuel

Solution

Inspect, clean and/or replace spark plugs

See your Polaris dealer

Set gap to specs or replace plugs

Check all connections and tighten

Replace with new fuel

Low battery voltage

Recharge battery to 12.5 VDC

Inspect and replace

Kinked or plugged fuel vent line

Incorrect fuel

Replace with recommended fuel

Inspect and clean or replace

See your Polaris dealer

Clogged air filter

Reverse speed limiter malfunction

Electronic throttle control malfunction

Other mechanical failure

See your Polaris dealer

Possible Lean Fuel Mixture Cause Solution

Low or contaminated fuel

Low octane fuel

Add or change fuel, clean the fuel system

Replace with recommended fuel

Replace filter

Clogged fuel filter

Incorrect jetting

See your Polaris dealer

Possible Rich Fuel Mixture Cause Solution

Overuse of choke

Fuel is very high octane

Incorrect jetting

Inspect, clean and/or replace spark plugs

Replace with lower octane fuel

See your Polaris dealer

119

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TROUBLESHOOTING

Engine Stops or Loses Power

Possible Cause

Solution

Out of fuel

Turn fuel valve to reserve, refuel

Inspect and replace

Kinked or plugged fuel vent line

Water present in fuel

Replace with new fuel

Overuse of choke

Inspect, clean and/or replace spark plugs

See your Polaris dealer

Fouled or defective spark plugs

Worn or defective spark plug wires

Incorrect spark plug gap or heat range

Loose ignition connections

Low battery voltage

Set gap to specs or replace plugs

Check all connections and tighten

Recharge battery to 12.5 VDC

Replace with recommended fuel

Inspect and clean or replace

See your Polaris dealer

Incorrect fuel

Clogged air filter

Reverse speed limiter malfunction

Electronic throttle control malfunction

Other mechanical failure

Overheated engine

See your Polaris dealer

Clean radiator screen and core

Clean engine exterior

See your Polaris dealer

Engine Overheating

Possible Cause

Solution

Debris lodged in screen

Remove and clean the screen. Pull on the

top portion of the screen, then remove the

lower portion.

Plugged Radiator

Use a garden hose to flush any debris

from the radiator fins. NOTE: High pres-

sure washers can deform the radiator fins

and reduce cooling efficiency.

120

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POLARIS PRODUCTS

Part No.

Description

Engine Lubricant

2870791

2871281

2871844

Fogging Oil (12 oz. Aerosol)

Engine Oil (qt.) Premium 4 Synthetic 0W-40 (4-Cycle)

Engine Oil (gal.) Premium 4 Synthetic 0W-40 (4-Cycle)

Gearcase / Transmission Lubricants

Premium Synthetic Gearcase Lubricant (1 gal.)

Premium Synthetic Gearcase Lubricant (12 oz. bottle)

Gear Drive Fluid (12 oz.)

2871477

2871478

2871653

2872276

2870465

2871654

2872277

Gear Drive Fluid (2.5 gal.)

Oil Pump for Gearcase Oil

Premium Drive Hub Fluid (8 oz.)

Premium Drive Hub Fluid (2.5 gal.)

Grease / Specialized Lubricants

Premium All Season Grease (3 oz. cartridge)

Premium All Season Grease (14 oz. cartridge)

Starter Drive Grease

2871322

2871423

2871460

2871515

2871551

2871312

2871329

Premium U-Joint Lube (3 oz.)

Premium U-Joint Lube (14 oz.)

Grease Gun Kit

Dielectric Grease (Nyogelt)

Coolant

2871323

2871534

60/40 Coolant (Gallon)

60/40 Coolant (Quart)

Additives / Miscellaneous

Carbon Clean Plus (12 oz.)

Fuel Stabilizer (16 oz.)

DOT3 Brake Fluid

2871326

2870652

2870990

2872893

Engine Degreaser

121

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SPECIFICATIONS

SPORTSMAN 400

Gross Vehicle Weight

Towing Capacity

1200 lbs./544 kg

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

Rear Rack Capacity

Overall Length

Overall Width

Overall Height

Wheelbase

90 lbs./40.8 kg

180 lbs./81.6 kg

81 in./205.7 cm

46 in./119.3 cm

47 in./119.4 cm

50.5 in./128.3 cm

11 in./27.9 cm

697 lbs./316 kg

65 in./165 cm

4.75 gal./18 l

2 qts./1.9 l

Ground Clearance

Dry Weight

Minimum Turning Radius

Fuel Capacity

Engine Oil Capacity

Coolant Capacity

Engine

3.2 qts./3.02 l

EH42PLE05

425

Displacement

Bore x Stroke

Pilot Jet

87.9 x 70

Main Jet

167.5

Needle Jet

Q-0 (829)

Jet Needle

4GAC33-3

Pilot Screw

2 3/4 turn (taper 12.5°)

250 w

Alternator Output

Compression Ratio

Carburetor

9:2 Full Stroke

BST 34mm

Ignition System

Ignition Timing

Spark Plug / Gap

Lubrication System

Driving System Type

Digital CDI

30° +/-- 2° @ 5000 RPM

NGK BKR5E / 0.9 mm / .036 in

Dry Sump

Dual sensing, automatic PVT (Polaris

Variable Transmission)

122

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SPECIFICATIONS

SPORTSMAN 400

Shift Type

Side Lever (High, Low, Neutral, Reverse)

Gear Reduction - Low

Gear Reduction - Reverse

Gear Reduction - Forward

Drive Ratio - Front

Drive Ratio - Final

Tire, Front

8.27/1

5.17/1

3.34/1

2:1

3.16:1

25 x 8 - 12 (5 psi)

Tire, Rear

25 x 11 - 12 (5 psi)

Front Brake

Hydraulic Disc

Rear Brake

Hydraulic, opposed piston caliper, fixed disc

Hydraulic lock, all wheel

MacPherson Strut, 6.7”

Full independent with anti-roll bar, 9.5”

CAM

Auxiliary Brake

Parking Brake

Front Suspension

Rear Suspension

Shock Adjustment

Headlight

1 - Single Beam on handlebar (50 w)

2 - Single Beam on grill (27 w)

Taillights

8.26 w

26.9 w

LCD

Brakelight

Instrument Cluster

Jetting and Clutching Charts (Sportsman 400)

Altitude

AMBIENT

TEMPERATURE

Below 40° F

Below 5° C

+40° F and above

+5° C and above

0-1800

172.5

165

167.5

160

Meters

(Feet)

(0-6000)

1800-3700

(6000-12000)

Altitude

Shift

Weight

Drive Clutch

Spring

Driven

Clutch

Spring

Helix

and Spring

Setting

Meters

(Feet)

0-1800

(0-6000)

10 BH

Blue/Green

Black

41-37°

PN 5132344

2+2

PN 5630711 PN 7041157 PN 7041782

1800-3700

(6000-12000)

20-40

Blue/Green

Black

41-37°

PN 5132344

2+2

PN 5631356 PN 7041157 PN 7041782

123

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SPECIFICATIONS

SPORTSMAN 500

Gross Vehicle Weight

1200 lbs./544 kg

1225 lbs./556 kg

1786 lbs./810 kg

Hitch Towing Rating

Unbraked Trailer Towing Capacity*

Hitch Tongue Capacity

120 lbs./54 kg (Rear rack weight and tongue

weight not to exceed 180 lbs./81.6 kg)

Front Rack Capacity

Rear Rack Capacity

Overall Length

Overall Width

Overall Height

Wheelbase

90 lbs./40.8 kg

180 lbs./81.6 kg

81 in./205.7 cm

46 in./116.8 cm

47 in./119.4 cm

50.5 in./128.3 cm

11 in./27.9 cm

697 lbs./316 kg

65 in./165 cm

4.75 gal./18 l

2 qts./1.9 l

Ground Clearance

Dry Weight

Minimum Turning Radius

Fuel Capacity

Engine Oil Capacity

Coolant Capacity

Engine

3.2 qts./3.02 l

EH50PLE13

498

Displacement

Bore x Stroke

Pilot Jet

92 x 75

Main Jet

152.5

Needle Jet

X-6M (896)

6MGH1-94-3

2 Turn

Jet Needle

Pilot Screw

Alternator Output

Compression Ratio

Carburetor

250 w

10:2 Full Stroke

BST 40mm

Ignition System

Ignition Timing

Spark Plug / Gap

Lubrication System

CDI

30 BTDC @ 5000 RPM

NGK BKR6E / 0.9 mm / .036 in

Dry Sump

* Based on EU Directive 76/432/EC

124

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SPECIFICATIONS

SPORTSMAN 500

Driving System Type

Shift Type

EBS

Side Lever (High, Low, Neutral, Reverse)

Gear Reduction - Low

Gear Reduction - Reverse

Gear Reduction - Forward

Drive Ratio - Front

Drive Ratio - Final

Tire, Front

8.27/1

5.17/1

3.34/1

2:1

3.16:1

25 x 8 - 12 (5 psi)

Tire, Rear

25 x 11 - 12 (5 psi)

Front Brake

Hydraulic Disc

Rear Brake

Hydraulic, opposed piston caliper, fixed disc

Hydraulic lock, all wheel

MacPherson Strut, 6.7”

Auxiliary Brake

Parking Brake

Front Suspension

Rear Suspension

Progressive rate, full independent with anti-

roll bar, 9.5”

Shock Adjustment

Headlight

CAM

1 Single Beam on Handlebar (50 w)

2 Single Beam on Grill (27 w)

Taillights

8.26 w

26.9 w

LCD

Brakelight

Instrument Cluster

Jetting and Clutching Charts (Sportsman 500)

Altitude

AMBIENT

TEMPERATURE

Below 40° F

Below 5° C

+40° F and above

+5° C and above

0-1800

(0-6000)

157.5

152.5

Meters

(Feet)

1800-3700

(6000-12000)

150

145

Altitude

Shift

Weight

Drive Clutch

Driven Clutch

Helix*

Spring

0-1800

(0-6000)

10 WH

Blue/Green

White/Yellow

PN 7041635

EBS

PN 5131674

Meters

(Feet)

PN 5630710 PN 7041157

1800-3700

10 RH

Blue/Green

White/Yellow

PN 7041635

EBS

PN 5131674

(6000-12000) PN 5630709 PN 7041157

*EBS models require no helix / spring adjustment

125

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SPECIFICATIONS

SPORTSMAN 600

Gross Vehicle Weight

Fuel Capacity

1240 lbs./563 kg

4.75 gal./18 l

Towing Capacity

1500 lbs./681 kg

Hitch Tongue Capacity

150 lbs./68.1 kg (Rear rack capacity and

tongue weight not to exceed 200 lbs./90.7 kg)

Front Rack Capacity

Rear Rack Capacity

Overall Length

Overall Width

Overall Height

Wheelbase

100 lbs./45.4 kg

200 lbs./90.8 kg

85 in./215.9 cm

46 in./116.8 cm

47 in./119.4 cm

50.75 in./128.9 cm

11 in./27.9 cm

740 lbs./336 kg

76 in./193 cm unloaded

2 qts./1.9 l

Ground Clearance

Dry Weight

Minimum Turning Radius

Engine Oil Capacity

Coolant Capacity

Engine

3.2 qts./3 l

EH059OLE021

597

Displacement

Bore x Stroke

Pilot Jet

76.5 x 65

Main Jet

155

Needle Jet

P-4

Jet Needle

J8-4FA01-3

Pilot Screw

1.5

Alternator Output

Compression Ratio

Starting System

Carburetor

300 Watts @ 3000 rpm

10.3:1

Electric

BST 34mm

Ignition System

Ignition Timing

Spark Plug / Gap

Lubrication System

Driving System Type

CDI

25° @ 2750 +/-- 250 RPM

RC7YC / 0.9 mm / .035 in

Pressurized Wet Sump

4 Wheel Independent Shaft

126

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SPECIFICATIONS

SPORTSMAN 600

Shift Type

Side Lever

(High, Low, Neutral, Reverse, Park)

Gear Reduction - Low

Gear Reduction - Reverse

Gear Reduction - High

Drive Ratio - Front:

Drive Ratio - Final

Tire Size - Front

Tire Size - Rear

7.5/1

5.11/1

3.09/1

3.82/1

3.10/1

25 x 8 - 12

25 x 11 - 12

Front Brake

Hydraulic Disc

Rear Brake

Hydraulic

Parking Brake

Hydraulic lock, all wheel

Headlight (watts)

1 - Single Beam on Handlebar (50)

2 - Single Beam on Grill (27)

Taillights (watts)

Brake Light (watts)

Instrument Cluster

8.26

26.9

LCD

Jetting and Clutching Charts (Sportsman 600)

Altitude

AMBIENT

Below 40° F

+40° F and above

TEMPERATURE

Below 5° C

+5° C and above

Meters

(Feet)

0-1800

(0-6000)

162.5

155

1800-3700

(6000-12000)

150

145

Altitude

Shift

Weight

Drive Clutch

Spring

Driven

Clutch

Spring

Helix*

Meters

(Feet)

0-1800

(0-6000)

10 MH

Blue/Green White/Yellow

EBS

PN 5630513 PN 7041157 PN 7041635 PN 5132751

1800-3700

(6000-12000)

10 WH

Blue/Green White/Yellow

EBS

PN 5630710 PN 7041157 PN 7041635 PN 5132751

EBS models require no helix / spring adjustment

127

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SPECIFICATIONS

SPORTSMAN 700

Gross Vehicle Weight

Fuel Capacity

1240 lbs./563 kg

4.75 gal./18 l

Towing Rating

1500 lbs./681 kg

1914 lbs./868 kg

100 lbs./45.4 kg

200 lbs./90.7 kg

150 lbs./68.1 kg (Rear rack capacity and

tongue weight not to exceed 200 lbs./90.8 kg)

81 in./205.7 cm

46 in./116.8 cm

47 in./119.4 cm

50.75 in./128.9 cm

11 in./27.9 cm

740 lbs./336 kg

76 in./193 cm unloaded

2 qts./1.9 l

Unbraked Trailer Towing Capacity*

Front Rack Capacity

Rear Rack Capacity

Hitch Tongue Capacity

Overall Length

Overall Width

Overall Height

Wheelbase

Ground Clearance

Dry Weight

Minimum Turning Radius

Engine Oil Capacity

Coolant Capacity

Engine

Displacement

Bore x Stroke

Pilot Jet

3.2 qts./3 l

EH68ALOE11

683

80 x 68

47.5

Main Jet

155

Needle Jet

P-6(829)

Jet Needle

J8-4FA01

Pilot Screw

1.0

Alternator Output

Compression Ratio

Starting System

Carburetor

330 Watts @ 3000 rpm

9.78:1

Electric

BST 34mm

Ignition System

Ignition Timing

Spark Plug / Gap

Lubrication System

Driving System Type

CDI

8 BTDC @ 2000 RPM

RC7YC / 0.9 mm / .035 in

Pressurized Wet Sump

4 Wheel Independent Shaft

* Based on EU Directive 76/432/EC

128

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SPECIFICATIONS

SPORTSMAN 700

Shift Type

Side Lever

(High, Low, Neutral, Reverse, Park)

Gear Reduction - Low

Gear Reduction - Reverse

Gear Reduction - High

Drive Ratio - Front:

Drive Ratio - Final

Tire Size - Front

Tire Size - Rear

7.5/1

5.11/1

2.89/1

3.82/1

3.10/1

25 x 8 - 12

25 x 11 - 12

Front Brake

Hydraulic Disc

Rear Brake

Hydraulic

Parking Brake

Hydraulic lock, all wheel

Headlight (watts)

1 - Single Beam on Handlebar (50)

2 - Single Beam on Grill (27)

Taillights (watts)

Brake Light (watts)

Instrument Cluster

8.26

26.9

LCD

Jetting and Clutching Charts (Sportsman 700)

Altitude

AMBIENT

Below 40° F

+40° F and above

TEMPERATURE

Below 5° C

+5° C and above

Meters

(Feet)

0-1800

(0-6000)

160

155

1800-3700

(6000-12000)

147.5

142.5

Altitude

Shift

Weight

Drive Clutch

Spring

Driven

Clutch

Spring

Helix*

Meters

(Feet)

0-1800

(0-6000)

20-56

Blue/Green White/Yellow

EBS

PN 5631315 PN 7041157 PN 7041635 PN 5132751

1800-3700

(6000-12000)

20-54

Blue/Green White/Yellow

EBS

PN 5631214 PN 7041157 PN 7041635 PN 5132751

EBS models require no helix / spring adjustment

129

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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 failure due to defects. This warranty covers the parts and labor

charges for repair or replacement of defective parts which are covered

by this warranty. This warranty begins on the date of purchase. This

warranty is transferrable to another consumer during the warranty

period through a Polaris dealer.

REGISTRATION

At the time of sale, the Warranty Registration Form must be completed

by your dealer and submitted to Polaris within ten days. Upon receipt

of this registration, Polaris will record the registration for warranty.

THE PURCHASER MUST COMPLETE AN ATV SAFETY

TRAINING COURSE PROVIDED BY THE DEALER IN ORDER

TO HAVE VALID WARRANTY ON THE ATV. No verification of

registration will be sent to the purchaser as the copy of the Warranty

Registration Form will be the warranty entitlement. If you have not

signed the original registration and received the customer copy, please

contact your dealer immediately. NO WARRANTY COVERAGE

WILL BE ALLOWED UNLESS YOUR ATV IS REGISTERED

WITH POLARIS.

Initial dealer preparation and set-up of your ATV is very important in

ensuring trouble-free operation. Purchasing a machine in the crate or

without proper dealer set-up will void your warranty coverage.

130

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WARRANTY

WARRANTY COVERAGE AND EXCLUSIONS:

LIMITATIONS OF WARRANTIES AND REMEDIES

The Polaris limited warranty excludes any failures that are not caused

by a defect in material or workmanship. This warranty does not cover

accidental damage, normal wear and tear, abuse or improper handling.

This warranty also does not cover any ATV that has been altered

structurally, modified, neglected, improperly maintained, used for

racing, or used for purposes other than for which it was manufactured,

or for any damages which occur during trailer transit or as a result of

unauthorized service or the use of unauthorized parts. In addition, this

warranty does not cover physical damage to paint or finish, stress

cracks, tearing or puncturing of upholstery material, corrosion, or

defects in parts, components or the ATV due to fire, explosions or any

other cause beyond Polaris’ control.

This warranty does not cover the use of unauthorized lubricants,

chemicals, or fuels that are not compatible with the ATV. The

exclusive remedy for breach of this warranty shall be, at Polaris’

exclusive option, repair or replacement of any defective materials, or

components or products. THE REMEDIES SET FORTH IN THIS

WARRANTY ARE THE ONLY REMEDIES AVAILABLE TO ANY

PERSON FOR BREACH OF THIS WARRANTY. POLARIS SHALL

HAVE NO LIABILITY TO ANY PERSON FOR INCIDENTAL,

CONSEQUENTIAL OR SPECIAL DAMAGES OF ANY

DESCRIPTION, WHETHER ARISING OUT OF EXPRESS OR

IMPLIED WARRANTY OR ANY OTHER CONTRACT,

NEGLIGENCE, OR OTHER TORT OR OTHERWISE. Some states

do not permit the exclusion or limitation of incidental or consequential

damages or implied warranties, so the above limitations or exclusions

may not apply to you if inconsistent with controlling state law.

131

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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 do not allow

limitations on how long an implied warranty lasts, so the above

limitation may not apply to you if inconsistent with controlling state

law.

HOW TO OBTAIN WARRANTY SERVICE

If your ATV requires warranty service, you must take it to a Polaris

dealer authorized to repair Polaris ATVs. When requesting warranty

service you must present your copy of the Warranty Registration form

to the dealer. (THE COST OF TRANSPORTATION TO AND FROM

THE DEALER IS YOUR RESPONSIBILITY). Polaris suggests that

you use your original selling dealer; however, you may use any Polaris

Servicing Dealer to perform warranty service.

Please work with your dealer to resolve any warranty issues. Should

your dealer require any additional assistance they will contact the

appropriate person at Polaris.

This warranty gives you specific legal rights, and you may also have

other rights which vary from state to state.

If any of the above terms are void because of state or federal law, all

other warranty terms will remain in effect.

Engine Oil

1. Mixing oil brands or using non-recommended oil may cause engine

damage. We recommend the use of Polaris engine oil for your ATV.

2. Damage resulting from the use of non-recommended lubricants may

not be covered by warranty.

132

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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 export from Polaris Industries. Dealers may not give authorization

for export. You should consult an authorized dealer to determine this

vehicle’s warranty or service bulletin coverage if you have any ques-

tions.

This policy does not apply to vehicles registered to government offi-

cials or military personnel on assignment outside the country of the

selling dealer’s authorized location.

This policy does not apply to Safety Recalls.

How to Get Service

In the Country where your vehicle was purchased:

Warranty or Service Bulletin repairs must be done by an authorized

Polaris dealer. If you move or are traveling within the country where

your vehicle was purchased, Warranty or Service Bulletin repairs may

be requested from any authorized Polaris dealer who sells the same line

as your vehicle.

Outside the Country where your vehicle was purchased:

If you are traveling temporarily outside the country where your vehicle

was purchased, you should take your vehicle to an authorized Polaris

dealer. You must show the dealer photo identification from the country

of the selling dealer’s authorized location as proof of residence. Upon

residence verification, the servicing dealer will be authorized to per-

form the warranty repair.

If You Move:

If you move to another country, be sure to contact Polaris Customer

Assistance and the customs department of the destination country be-

fore you move. Vehicles importation rules vary considerably from

country to country. You may be required to present documentation of

your move to Polaris Industries in order to continue your warranty cov-

erage. You may also be required to obtain documentation from Polaris

Industries in order to register your vehicle in your new country.

133

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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 the country where it was pur-

chased, and you have not followed the procedure set out above, your

vehicle will no longer be eligible for warranty or service bulletin cover-

age of any kind. (Vehicles registered to Government officials or mili-

tary personnel on assignment outside of the country where the vehicle

was purchased will continue to be covered by the basic warranty.)

For questions call Polaris Customer Assistance:

United States: 1-763-417-8650

Canada: 1-204-925-7100

134

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INDEX

Accessories . . . . . . . . . . . . . . . . . . . . 110

ADJUSTMENTS . . . . . . . . . . . 114-116

Age Restrictions . . . . . . . . . . . . . . . . . 11

Air Filter Service . . . . . . . . . . . . . . . . 96

All Wheel Drive . . . . . . . . . . . . . . . . . 44

Automatic Transmission . . . . . . . . . . . 43

Auxiliary Brake . . . . . . . . . . . . . . . . . 91

AWD . . . . . . . . . . . . . . . . . . . . . . . . . . 44

Electrical Switches . . . . . . . . . . . . . . . 36

EMISSION CONTROL SYSTEMS . . 68

Engaging Front Gearcase . . . . . . . . . . 44

Engine Cooling System . . . . . . . . . . . 89

Engine Stop Switch . . . . . . . . . . . . . . 36

Exhaust Emission Control System . . . 68

Equipment Modifications . . . . . . . . . . 15

FEATURES . . . . . . . . . . . . . . . . . . 44-49

Filter Systems . . . . . . . . . . . . . . . . . . . 96

Front Gearcase Oil (400/500) . . . . . . . 84

Front Gearcase Oil (600/700) . . . . . . . 86

Front Wheel Hub Tightening . . . . . . . 95

Fuel Filter . . . . . . . . . . . . . . . . . . . . . . 42

Fuel Safety . . . . . . . . . . . . . . . . . . . . . 50

Fuel Tank . . . . . . . . . . . . . . . . . . . . . . 42

Fuel Valve . . . . . . . . . . . . . . . . . . . . . . 42

Battery . . . . . . . . . . . . . . . . . . . 107-109

Battery (Conventional) . . . . . . . . . . . 106

Battery Charging (Sealed) . . . . 108-109

Battery Fluid (Conventional) . . . . . . 108

Battery Installation . . . . . . . . . . . . . . 107

Battery Removal . . . . . . . . . . . . . . . . 107

Battery Storage . . . . . . . . . . . . . . . . . 108

Belt Life . . . . . . . . . . . . . . . . . . . . . . . 43

Brake Fluid . . . . . . . . . . . . . . . . . . 39, 41

Brake Lever . . . . . . . . . . . . . . . . . . . . 38

Brake, Auxiliary . . . . . . . . . . . . . . . . . 41

Brake, Front . . . . . . . . . . . . . . . . . . . . 90

Brake, Rear . . . . . . . . . . . . . . . . . . . . . 91

Break-In Period . . . . . . . . . . . . . . . . . 51

Breather Filter . . . . . . . . . . . . . . . . . . 96

Gear Selector . . . . . . . . . . . . . . . . . . . 43

Handlebars . . . . . . . . . . . . . . . . . . . . 114

Hauling Cargo . . . . . . . . . . . . . . . 55-56

Headlamp Removal/Installation . . . . 100

Headlight Housing Replacement . . . . 99

Headlight Lamp Replacement . . . . . . 97

High Beam Adjustment . . . . . . . . . . . 98

High Range . . . . . . . . . . . . . . . . . . . . 104

Hour Meter . . . . . . . . . . . . . . . . . . . . . 47

Camber and Caster . . . . . . . . . . . . . . 114

Carburetor/Idle RPM . . . . . . . . . . . . 115

Choke . . . . . . . . . . . . . . . . . . . . . . . . . 42

Cleaning . . . . . . . . . . . . . . . . . . 110-113

Clutching Chart (400) . . . . . . . . . . . 123

Clutching Chart (500) . . . . . . . . . . . 125

Clutching Chart (600) . . . . . . . . . . . 127

Clutching Chart (700) . . . . . . . . . . . 129

Cold Weather Operation . . . . . . . . . . . 54

CONTROLS . . . . . . . . . . . . . . . . . 36-43

Coolant Level . . . . . . . . . . . . . . . . . . . 88

Cooling System . . . . . . . . . . . . . . . . . 88

Crankcase Emission Control System . 68

Instrument Cluster . . . . . . . . . . . . 45-49

Jetting/Clutching (400) . . . . . . . . . . 123

Jetting/Clutching (500) . . . . . . . . . . 125

Jetting/Clutching (600) . . . . . . . . . . 127

Jetting/Clutching (700) . . . . . . . . . . 129

K-turn . . . . . . . . . . . . . . . . . . . . . . . . . 63

Diagnostic Mode . . . . . . . . . . . . . 48-49

Driving in Reverse . . . . . . . . . . . . . . . 66

Driving on Slippery Surfaces . . . . . . . 59

Driving Over Obstacles . . . . . . . . . . . 65

Driving Procedures . . . . . . . . . . . . . . . 57

Driving Safely . . . . . . . . . . . . . . . 57-67

Driving Through Water . . . . . . . . . . . 64

Light Switches . . . . . . . . . . . . . . . . . . 38

Lights . . . . . . . . . . . . . . . . . . . . . 97-100

Low Range . . . . . . . . . . . . . . . . . . . . 104

Lubrication Guide . . . . . . . . . . . . 76-77

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INDEX

Main Switch . . . . . . . . . . . . . . . . . . . . 36

MAINTENANCE

AND LUBRICATION . . . . 69-113

Maintenance Record . . . . . . . . . . . . . . 74

Making Turns . . . . . . . . . . . . . . . . . . . 58

Master Cylinder . . . . . . . . . . . . . . . . . 39

Sidehilling . . . . . . . . . . . . . . . . . . . . . 61

Spark Arrestor . . . . . . . . . . . . . . . . . 103

Spark Plug Replacement . . . . . . . . . 101

Spark Plugs . . . . . . . . . . . . . . . . . . . . 101

SPECIFICATIONS . . . . . . . . . . 122-129

Starting a Cold Engine . . . . . . . . . . . . 53

Starting a Warm Engine . . . . . . . . . . . 54

Starting the Engine . . . . . . . . . . . . 53-54

Steering Assembly . . . . . . . . . . . . . . . 92

Storage . . . . . . . . . . . . . . . . . . . 110-113

Storage Tips . . . . . . . . . . . . . . . 111-113

Noise Emission Control System . . . . . 68

Odometer . . . . . . . . . . . . . . . . . . . . . . 47

Oil Change . . . . . . . . . . . . . . . . . . . . . 80

Oil Change (400/500) . . . . . . . . . . 80-81

Oil Change (600/700) . . . . . . . . . . . . . 82

Oil Check . . . . . . . . . . . . . . . . . . . . . . 79

Oil Filter Change . . . . . . . . . . . . . . . . 80

OPERATION . . . . . . . . . . . . . . . . 50-67

Operator Safety . . . . . . . . . . . . . . 11-35

Override Switch . . . . . . . . . . . . . . . . . 36

TABLE OF CONTENTS . . . . . . . . . . . . 5

Tachometer . . . . . . . . . . . . . . . . . . . . . 47

Taillight/Brakelight

Lamp Replacement . . . . . . . . . 100

Throttle Cable Freeplay . . . . . . . . . . 116

Throttle Lever . . . . . . . . . . . . . . . . . . . 37

Tires . . . . . . . . . . . . . . . . . . . . . . . . . . 94

Toe Alignment . . . . . . . . . . . . . . . . . . 92

Transmission Oil (400/500) . . . . . . . . 83

Transmission Oil (600/700) . . . . . . . . 85

Transporting the ATV . . . . . . . . . . . . 113

Traveling Downhill . . . . . . . . . . . . . . 62

Traveling Uphill . . . . . . . . . . . . . . . . . 60

Trip Meter . . . . . . . . . . . . . . . . . . . . . 47

TROUBLESHOOTING . . . . . . 117-120

Turning Around on a Hill . . . . . . . . . . 63

Parking Brake . . . . . . . . . . . . . . . . . . . 40

Parking on an Incline . . . . . . . . . . . . . 67

Periodic Maintenance Schedule . . 69-73

POLARIS PRODUCTS . . . . . . . . . . . 121

Pre-Ride Inspection . . . . . . . . . . . . . . 52

Premium 4 Synthetic Lubricant . . . . . 78

PVT Drying . . . . . . . . . . . . . . . . . . . 105

PVT System . . . . . . . . . . . . . . . 104-105

USFS Approved Spark Arrestor . . . . . 68

Radiator Coolant Level . . . . . . . . . . . 89

Rear Gearcase Oil (600/700) . . . . . . . 87

Rear Spring . . . . . . . . . . . . . . . . . . . . 114

Rider Information Center . . . . . . . 46-49

VEHICLE IDENTIFICATION

NUMBERS . . . . . . . . . . . . . . . . . . 4

Vehicle Immersion . . . . . . . . . . . . . . 102

Safe Riding Gear . . . . . . . . . . . . . . . . 10

SAFETY . . . . . . . . . . . . . . . . . . . . . 6-35

Safety Decals and Locations . . . . . . 6-9

Safety Training . . . . . . . . . . . . . . . . . . 11

Setting the Parking Brake . . . . . . . . . . 40

Side Panel Removal . . . . . . . . . . . . . . 93

WARRANTY . . . . . . . . . . . . . . 130-132

WELCOME . . . . . . . . . . . . . . . . . . . . . 3

Wheel Installation . . . . . . . . . . . . . . . 95

Wheel Nut Torque Specifications . . . . 95

Wheel Removal . . . . . . . . . . . . . . . . . 94

136

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WARNING

Improper vehicle use can result in SEVERE INJURY or DEATH.

NEVER CARRY

PASSENGERS

NEVER USE

ON PUBLIC

ROADS

NEVER USE

WITH DRUGS

OR ALCOHOL

ALWAYS USE

AN APPROVED

HELMET AND

PROTECTIVE

GEAR

NEVER:

Operate without proper training or instruction.

Operate on public roads. A collision can occur with another vehicle.

Operate at speeds too fast for your skills or the conditions.

Use ALCOHOL or DRUGS before or while operating this vehicle.

Carry Passengers.

ALWAYS:

Avoid paved surfaces, which may adversely affect handling and control.

Use proper RIDING TECHNIQUES to avoid vehicle overturns on hills

and rough terrain, and in turns.

Wear eye protection, helmet and protective apparel.

READ OWNER'S MANUAL.

FOLLOW ALL INSTRUCTIONS AND WARNINGS.

Part No. 9918540 Rev 04

PRINTED IN THE USA

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