Owners Manual
Page 6
... which would cause the vehicle to lean sharply to turn the ATV around and remount, following the procedure described in this manual for carrying cargo or pulling a trailer. Shift your weight forward. When it is safe to either side if pointed straight uphill. Always maintain proper tire pressure as described in this manual. Dismount on level ground. • Always follow...
... which would cause the vehicle to lean sharply to turn the ATV around and remount, following the procedure described in this manual for carrying cargo or pulling a trailer. Shift your weight forward. When it is safe to either side if pointed straight uphill. Always maintain proper tire pressure as described in this manual. Dismount on level ground. • Always follow...
Owners Manual
Page 16
... emergency when engine shut off is moving. 7075413 6 Start on hills, avoid sudden use in forward and don't leave brake engaged for use of controls. If vehicle slides backwards down hill, apply hand brakes with wet brakes or on grades, leave the gear shift in event of throttle failure or other contaminants can result in Owner's Manual before trying steeper terrain. PARK BRAKE MAY...
... emergency when engine shut off is moving. 7075413 6 Start on hills, avoid sudden use in forward and don't leave brake engaged for use of controls. If vehicle slides backwards down hill, apply hand brakes with wet brakes or on grades, leave the gear shift in event of throttle failure or other contaminants can result in Owner's Manual before trying steeper terrain. PARK BRAKE MAY...
Owners Manual
Page 18
.... Tow only from tow hooks or hitch. 7074954 6 WARNING (Found on models with racks) 8 Please refer to reduce the risk of 18 increases your Owner's Manual for details. 7072724 (Found on models with no racks) 4 3 WARNING UNDER 18 Operating this ATV if you are under age 18. 7074827 DO NOT TOW FROM RACK OR BUMPER. SAFETY WARNING AND OPERATION DECALS 5 7 WARNING OVER-LOADING CAN CAUSE STEERING, TIPPING AND BRAKING PROBLEMS...
.... Tow only from tow hooks or hitch. 7074954 6 WARNING (Found on models with racks) 8 Please refer to reduce the risk of 18 increases your Owner's Manual for details. 7072724 (Found on models with no racks) 4 3 WARNING UNDER 18 Operating this ATV if you are under age 18. 7074827 DO NOT TOW FROM RACK OR BUMPER. SAFETY WARNING AND OPERATION DECALS 5 7 WARNING OVER-LOADING CAN CAUSE STEERING, TIPPING AND BRAKING PROBLEMS...
Owners Manual
Page 19
... FRONT HEADLIGHT BEAM when carrying loads on the racks raises the center of gravity of the vehicle and creates a less stable operating condition. SAFETY WARNING AND OPERATION DECALS 7 This decal is necessary to maintain proper stability and operating characteristics. WARNING LOAD DISTRIBUTION WARNINGS Correct loading of the vehicle. Failure to maintain stable operating conditions. When operating at maximum cargo capacity, the cargo weight...
... FRONT HEADLIGHT BEAM when carrying loads on the racks raises the center of gravity of the vehicle and creates a less stable operating condition. SAFETY WARNING AND OPERATION DECALS 7 This decal is necessary to maintain proper stability and operating characteristics. WARNING LOAD DISTRIBUTION WARNINGS Correct loading of the vehicle. Failure to maintain stable operating conditions. When operating at maximum cargo capacity, the cargo weight...
Owners Manual
Page 23
... L'adjuster. See your Owner's Manual. 7074935 CAUTION VEHICLE LIGHTS WILL BURN OUT IF BATTERY IS DISCONNECTED DURING VEHICLE OPERATION. SEE YOUR OWNER'S MANUAL. 7074214 13 SAFETY WARNING AND OPERATION DECALS ATTENTION Specific carburetor jetting and adjustments are spinning. Factory setting: 40° to engage AWD if the rear wheels are required depending on temperature and altitude. Collapse Suspension To Adjust. See Owner's Manual. VERTICAL WEIGHT 30 LBS. at 0-3000...
... L'adjuster. See your Owner's Manual. 7074935 CAUTION VEHICLE LIGHTS WILL BURN OUT IF BATTERY IS DISCONNECTED DURING VEHICLE OPERATION. SEE YOUR OWNER'S MANUAL. 7074214 13 SAFETY WARNING AND OPERATION DECALS ATTENTION Specific carburetor jetting and adjustments are spinning. Factory setting: 40° to engage AWD if the rear wheels are required depending on temperature and altitude. Collapse Suspension To Adjust. See Owner's Manual. VERTICAL WEIGHT 30 LBS. at 0-3000...
Owners Manual
Page 24
... both tanks to drive chain adjustment 9. clean or replace 10. Operators helmet, goggles and clothing 13. Fuel and oil tanks - Headlight/Taillight/Brakelight - check for free operation and closing 5. Drive chain - check for proper level at the recovery bottle 14 Before riding your vehicle, inspect all indicator lights and switches 6. All brakes - check operation of wheel nuts and axle nuts; check for any area 11. Engine coolant - (Liquid Cooled Models...
... both tanks to drive chain adjustment 9. clean or replace 10. Operators helmet, goggles and clothing 13. Fuel and oil tanks - Headlight/Taillight/Brakelight - check for free operation and closing 5. Drive chain - check for proper level at the recovery bottle 14 Before riding your vehicle, inspect all indicator lights and switches 6. All brakes - check operation of wheel nuts and axle nuts; check for any area 11. Engine coolant - (Liquid Cooled Models...
Owners Manual
Page 52
... to define your dealer. Shift Patterns H N R L H N R WARNING 1. reverse; To change gears, stop the vehicle and with engine speed above idle or while the vehicle is left unattended. Should you own. Please check your Owner's Manual Supplement to extend belt life. reverse; and low forward or forward; Always place the transmission in gear with the parking brake applied and turn the vehicle off whenever the vehicle is moving or while operating...
... to define your dealer. Shift Patterns H N R L H N R WARNING 1. reverse; To change gears, stop the vehicle and with engine speed above idle or while the vehicle is left unattended. Should you own. Please check your Owner's Manual Supplement to extend belt life. reverse; and low forward or forward; Always place the transmission in gear with the parking brake applied and turn the vehicle off whenever the vehicle is moving or while operating...
Owners Manual
Page 53
..., release the throttle before getting into conditions where front wheel drive may be needed. CONTROL AND PARTS FUNCTIONS Demand 4 Drive (Found on models with a unique, Polaris exclusive, Demand 4 Drive (AWD) system which is in 2 wheel drive at all times. NOTE: The override switch also allows activation of time the vehicle may cause severe drive shaft and clutch damage. There is no limit to the length of Demand 4 Drive (AWD) in Demand 4 Drive. If...
..., release the throttle before getting into conditions where front wheel drive may be needed. CONTROL AND PARTS FUNCTIONS Demand 4 Drive (Found on models with a unique, Polaris exclusive, Demand 4 Drive (AWD) system which is in 2 wheel drive at all times. NOTE: The override switch also allows activation of time the vehicle may cause severe drive shaft and clutch damage. There is no limit to the length of Demand 4 Drive (AWD) in Demand 4 Drive. If...
Owners Manual
Page 60
... conditions, and cold weather riding. ADD 8 OZ. Do not overfill. Serious engine damage and voiding of stick consistent. 5. Shut engine off. 50 Remove dipstick and check to 120° F. Never substitute or mix oil brands. Oil and Filter Change The recommended oil change the oil filter whenever changing oil (Polaris PN 3084963) 1. Severe use includes continuous duty in more efficient operation, more power output and lower fuel consumption. CONTROL...
... conditions, and cold weather riding. ADD 8 OZ. Do not overfill. Serious engine damage and voiding of stick consistent. 5. Shut engine off. 50 Remove dipstick and check to 120° F. Never substitute or mix oil brands. Oil and Filter Change The recommended oil change the oil filter whenever changing oil (Polaris PN 3084963) 1. Severe use includes continuous duty in more efficient operation, more power output and lower fuel consumption. CONTROL...
Owners Manual
Page 61
... gear selector in -line oil filter. Do not allow hot oil to the upper mark on the drain plug and the oil tank should be hot. Using an oil filter wrench, turn after every 100 hours of burrs, nicks or scratches. Approximately 1 cup of used filter and oil properly. 13. 14. 15. 16. 17. 18. Reinstall dipstick. Filter Start engine and let it idle for leaks. Fuel Filter and Oil Filter Polaris...
... gear selector in -line oil filter. Do not allow hot oil to the upper mark on the drain plug and the oil tank should be hot. Using an oil filter wrench, turn after every 100 hours of burrs, nicks or scratches. Approximately 1 cup of used filter and oil properly. 13. 14. 15. 16. 17. 18. Reinstall dipstick. Filter Start engine and let it idle for leaks. Fuel Filter and Oil Filter Polaris...
Owners Manual
Page 67
... of warranty can build up and cause damage to close fitted engine parts. 5. Change at sustained idle. Fill fuel tank with vehicle operation and handling. Serious engine damage and voiding of a new engine will give you room to use . Drive slowly at full throttle or high speeds for your part is open and will result in oil and filter. Select an area which has a minimum pump...
... of warranty can build up and cause damage to close fitted engine parts. 5. Change at sustained idle. Fill fuel tank with vehicle operation and handling. Serious engine damage and voiding of a new engine will give you room to use . Drive slowly at full throttle or high speeds for your part is open and will result in oil and filter. Select an area which has a minimum pump...
Owners Manual
Page 69
... kg) No Rear Rack No Rear Rack No Rear Rack No Rear Rack Maximum trailer weight - 850 lbs.(386 kg); Sportsman 500 may tow up to extend belt life. 59 Do not tow any trailer on level ground only. If your machine is recommended in heavy pulling situations to 1250 (568 kg) on a grade steeper than 15°. Do not obstruct the headlight beam with a front rack, take care...
... kg) No Rear Rack No Rear Rack No Rear Rack No Rear Rack Maximum trailer weight - 850 lbs.(386 kg); Sportsman 500 may tow up to extend belt life. 59 Do not tow any trailer on level ground only. If your machine is recommended in heavy pulling situations to 1250 (568 kg) on a grade steeper than 15°. Do not obstruct the headlight beam with a front rack, take care...
Owners Manual
Page 71
... - check condition and pressures 2. check operation, adjustment and fluid level (includes auxiliary brake) 4. check for dirt; check for any unusual looseness in proper working order. clean or replace 10. visually inspect vehicle for proper function 7. fill both tanks to drive chain adjustment 9. check for proper level at the recovery bottle 61 Fuel and oil tanks - Wheels - Operators helmet, goggles and clothing 13. Engine coolant - (Liquid Cooled Models Only...
... - check condition and pressures 2. check operation, adjustment and fluid level (includes auxiliary brake) 4. check for dirt; check for any unusual looseness in proper working order. clean or replace 10. visually inspect vehicle for proper function 7. fill both tanks to drive chain adjustment 9. check for proper level at the recovery bottle 61 Fuel and oil tanks - Wheels - Operators helmet, goggles and clothing 13. Engine coolant - (Liquid Cooled Models Only...
Owners Manual
Page 89
...) J Injector Oil Filter (2-Cycle) Engine Counterbalance (400 Engines) Oil Pump Cable (2-Cycle) "L Engine breather filter (4 cycle) Engine breather hose (4 cycle) Engine Mounts Engine Cylinder Head and Cylinder Base Fasteners "L "L " JL Air Filter - Break in wet or dusty areas, should be performed by an authorized Polaris dealer. change Check when refueling Replace Check oil level; Inspect, clean, lubricate, adjust or replace parts as dirty or wet conditions Emission Control System Service (California - 4-Cycle) Item "L Engine Oil - Pre-Cleaner Air Filter - Vehicles subjected...
...) J Injector Oil Filter (2-Cycle) Engine Counterbalance (400 Engines) Oil Pump Cable (2-Cycle) "L Engine breather filter (4 cycle) Engine breather hose (4 cycle) Engine Mounts Engine Cylinder Head and Cylinder Base Fasteners "L "L " JL Air Filter - Break in wet or dusty areas, should be performed by an authorized Polaris dealer. change Check when refueling Replace Check oil level; Inspect, clean, lubricate, adjust or replace parts as dirty or wet conditions Emission Control System Service (California - 4-Cycle) Item "L Engine Oil - Pre-Cleaner Air Filter - Vehicles subjected...
Owners Manual
Page 90
... months 6 months monthly As required L J Idle Speed Throttle Cable/ETC Switch Choke (Enricher) Cable Coolant/Level Inspection Coolant strength/pressure test system Radiator Cooling System hoses Spark arrestor Recoil housing L " " " " " General Lubrication Front hubs/fluid check (AWD) Front hubs/fluid change (AWD) Front Gearcase OIl (shaft drive) Transmission Oil Level Shift linkage Check monthly and change annually Inspect, lubricate, adjust Change lubricant every two years Inspect-adjust, replace if necessary Inspect, clean Inspect daily...
... months 6 months monthly As required L J Idle Speed Throttle Cable/ETC Switch Choke (Enricher) Cable Coolant/Level Inspection Coolant strength/pressure test system Radiator Cooling System hoses Spark arrestor Recoil housing L " " " " " General Lubrication Front hubs/fluid check (AWD) Front hubs/fluid change (AWD) Front Gearcase OIl (shaft drive) Transmission Oil Level Shift linkage Check monthly and change annually Inspect, lubricate, adjust Change lubricant every two years Inspect-adjust, replace if necessary Inspect, clean Inspect daily...
Owners Manual
Page 93
... with a grease gun. Chain Adjusters (Center and Front Eccentrics) 21. Lower Control Arms 23. Always use , such as wet or dusty conditions. **Polaris Premium all Season Grease or grease conforming to NLGI No. 2, such as necessary. MAINTENANCE Lubrication Recommendations 14. Front A Arm Pivot Shaft 15. Counter Balance Housing (400) 16. Output Shaft Support Bearing 17. Rear Axle Bearing 19. Upper Control Arms 22. Check level...
... with a grease gun. Chain Adjusters (Center and Front Eccentrics) 21. Lower Control Arms 23. Always use , such as wet or dusty conditions. **Polaris Premium all Season Grease or grease conforming to NLGI No. 2, such as necessary. MAINTENANCE Lubrication Recommendations 14. Front A Arm Pivot Shaft 15. Counter Balance Housing (400) 16. Output Shaft Support Bearing 17. Rear Axle Bearing 19. Upper Control Arms 22. Check level...
Owners Manual
Page 118
... the switch. Before adjusting the oil pump, check engine idle RPM and carburetor adjustments which are found in step 2, making sure cover gasket is properly seated. Loosen throttle cable jam nut and turn adjuster in or out until marks align (D) when the throttle slide just begins to rise). 5. Lift boot up off adjuster sleeve. Tighten the locknut. 7. MAINTENANCE Oil Pump Adjustment Procedure 400 Engines 1. Remove the oil pump cover...
... the switch. Before adjusting the oil pump, check engine idle RPM and carburetor adjustments which are found in step 2, making sure cover gasket is properly seated. Loosen throttle cable jam nut and turn adjuster in or out until marks align (D) when the throttle slide just begins to rise). 5. Lift boot up off adjuster sleeve. Tighten the locknut. 7. MAINTENANCE Oil Pump Adjustment Procedure 400 Engines 1. Remove the oil pump cover...
Owners Manual
Page 140
... battery. Washing If a high pressure type car wash system is to the wheel bearings, transmission seals, body panels, brakes and warning labels. Use a professional type washing mitten, cleaning the upper body first and the lower parts last. Operate the starter for a few seconds and reinstall the spark plug. Lubricate suspension pivot points, lower steering post, all U-joints (if any) and rear axle fittings (if any water that might have entered the engine or exhaust...
... battery. Washing If a high pressure type car wash system is to the wheel bearings, transmission seals, body panels, brakes and warning labels. Use a professional type washing mitten, cleaning the upper body first and the lower parts last. Operate the starter for a few seconds and reinstall the spark plug. Lubricate suspension pivot points, lower steering post, all U-joints (if any) and rear axle fittings (if any water that might have entered the engine or exhaust...
Owners Manual
Page 155
... warranty lasts, so the above limitation may use Polaris engine oil. 2. POLARIS FURTHER DISCLAIMS ALL EXPRESS WARRANTIES NOT STATED IN THIS WARRANTY. Never substitute or mix oil brands as serious engine damage and voiding of the Warranty Registration form to perform warranty service. POLARIS ... WARRANTY SERVICE If your original selling dealer; If any of the above limitations or exclusions may also have other warranty terms will contact the appropriate person at Polaris' exclusive option, repair or replacement of any warranty issues. This warranty gives you specific ...
... warranty lasts, so the above limitation may use Polaris engine oil. 2. POLARIS FURTHER DISCLAIMS ALL EXPRESS WARRANTIES NOT STATED IN THIS WARRANTY. Never substitute or mix oil brands as serious engine damage and voiding of the Warranty Registration form to perform warranty service. POLARIS ... WARRANTY SERVICE If your original selling dealer; If any of the above limitations or exclusions may also have other warranty terms will contact the appropriate person at Polaris' exclusive option, repair or replacement of any warranty issues. This warranty gives you specific ...
Owners Manual
Page 156
...-127 Headlight Lamp Replacement . . 123-127 Indicator Lamp Replacement ...129 Indicator Lights ...36 Light Switches ...36 Load Capacity ...59 Lubricant, 2cycle ...52 Lubrication Recommendations ...82-87 Main Switch ...35 Battery ...73-74 Maintenance ...76-131 Maintenance Record ...88 Maintenance Schedule ...79-81 Making Turns ...63 Noise Control System ...75 Oil Change ...50-51 Oil Filter ...51 Oil Pump Adjustment ...108-109 Oil Pump Bleeding ...110 Oil System ...48-50 Operation Warnings ...15-33 Paint Codes ...133-134 Parking On...
...-127 Headlight Lamp Replacement . . 123-127 Indicator Lamp Replacement ...129 Indicator Lights ...36 Light Switches ...36 Load Capacity ...59 Lubricant, 2cycle ...52 Lubrication Recommendations ...82-87 Main Switch ...35 Battery ...73-74 Maintenance ...76-131 Maintenance Record ...88 Maintenance Schedule ...79-81 Making Turns ...63 Noise Control System ...75 Oil Change ...50-51 Oil Filter ...51 Oil Pump Adjustment ...108-109 Oil Pump Bleeding ...110 Oil System ...48-50 Operation Warnings ...15-33 Paint Codes ...133-134 Parking On...