Owners Manual
Page 10
... tall, off-center, or unsecured loads will severely damage the engine. Do not operate vehicle without the air filter element will increase your Owner's Manual. 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). With dual racks, load distribution 1/3 front 2/3 rear is best. Do not block headlight. S Clean pre-filter element often, more...
... tall, off-center, or unsecured loads will severely damage the engine. Do not operate vehicle without the air filter element will increase your Owner's Manual. 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). With dual racks, load distribution 1/3 front 2/3 rear is best. Do not block headlight. S Clean pre-filter element often, more...
Owners Manual
Page 12
... TRAILER MAX WEIGHT: 1225 LBS. (557 KG) ON LEVEL GROUND 850 LBS. (386 KG) UP TO 15° GRADE HITCH MAX. See Owner's Manual. 7079604 SAFETY ALL WHEEL DRIVE SWITCH Do not push switch to engage AWD if the rear wheels are spinning. VERTICAL WEIGHT: 150 LBS. (68KG) 7170509 Sportsman 600/700 9 Loss of control or forward flipover may result, especially in power and traction if too much throttle...
... TRAILER MAX WEIGHT: 1225 LBS. (557 KG) ON LEVEL GROUND 850 LBS. (386 KG) UP TO 15° GRADE HITCH MAX. See Owner's Manual. 7079604 SAFETY ALL WHEEL DRIVE SWITCH Do not push switch to engage AWD if the rear wheels are spinning. VERTICAL WEIGHT: 150 LBS. (68KG) 7170509 Sportsman 600/700 9 Loss of control or forward flipover may result, especially in power and traction if too much throttle...
Owners Manual
Page 18
... always maintain proper tire pressure. S Always check for braking. S Never exceed the stated load capacity for carrying cargo or towing. Cargo must be properly distributed and securely attached. Use only Polaris-approved accessories, and familiarize yourself with their function and effect on a Polaris ATV any other modifications to the vehicle, that may change the handling characteristics of tires specified for these purposes...
... always maintain proper tire pressure. S Always check for braking. S Never exceed the stated load capacity for carrying cargo or towing. Cargo must be properly distributed and securely attached. Use only Polaris-approved accessories, and familiarize yourself with their function and effect on a Polaris ATV any other modifications to the vehicle, that may change the handling characteristics of tires specified for these purposes...
Owners Manual
Page 45
...: For normal operation. Fuel Valve The fuel valve (1) is located directly below the handlebar. Refer to clean the fuel filter. 42 CONTROLS Choke The choke assists in -line fuel filter should be replaced by your dealer after every 100 hours of 87=(R+ M/2) octane. 2 1 Fuel Filter The in starting . OFF ON Fuel Tank The fuel tank filler cap (2) is located on page 53 for correct choke and throttle settings during starting a cold engine.
...: For normal operation. Fuel Valve The fuel valve (1) is located directly below the handlebar. Refer to clean the fuel filter. 42 CONTROLS Choke The choke assists in -line fuel filter should be replaced by your dealer after every 100 hours of 87=(R+ M/2) octane. 2 1 Fuel Filter The in starting . OFF ON Fuel Tank The fuel tank filler cap (2) is located on page 53 for correct choke and throttle settings during starting a cold engine.
Owners Manual
Page 46
... extend belt life, use low forward gear in PARK and lock the parking brake. To change gears, stop the vehicle, and with the engine speed above idle or while the vehicle is left unattended, always place the transmission in heavy pulling situations and when operating at less than seven miles per hour for extended periods of HIGH or PARK, it's not necessary to apply the brake. 1 H L N R P CAUTION Shifting gears with the engine idling...
... extend belt life, use low forward gear in PARK and lock the parking brake. To change gears, stop the vehicle, and with the engine speed above idle or while the vehicle is left unattended, always place the transmission in heavy pulling situations and when operating at less than seven miles per hour for extended periods of HIGH or PARK, it's not necessary to apply the brake. 1 H L N R P CAUTION Shifting gears with the engine idling...
Owners Manual
Page 47
... turned on . CAUTION Switching to the length of AWD in the instrument cluster will not disengage until the AWD switch is turned off. FEATURES All Wheel Drive (AWD) System Polaris 4-wheel drive ATVs are spinning may cause severe drive shaft and gearcase damage. See page 36. When the switch is off while the vehicle is on the right handlebar. Initially, the vehicle's electronic system will not enable the AWD until the engine...
... turned on . CAUTION Switching to the length of AWD in the instrument cluster will not disengage until the AWD switch is turned off. FEATURES All Wheel Drive (AWD) System Polaris 4-wheel drive ATVs are spinning may cause severe drive shaft and gearcase damage. See page 36. When the switch is off while the vehicle is on the right handlebar. Initially, the vehicle's electronic system will not enable the AWD until the engine...
Owners Manual
Page 49
... Voltage - Driving at start-up. When the last segment clears, a low fuel warning is located in : 4 5 6 3 H = High Range 7 L = Low Range N = Neutral R = Reverse 8 2 P = Park 2. Engine Hour Display Indicator 4. Fuel Gauge - Check Engine Warning Indicator - NOTE: If the instrument cluster fails to illuminate, a battery over-voltage may have occurred and the instrument cluster may also occur under normal operation if the machine is at idle and high electrical load (lights, cooling fan, accessories) is...
... Voltage - Driving at start-up. When the last segment clears, a low fuel warning is located in : 4 5 6 3 H = High Range 7 L = Low Range N = Neutral R = Reverse 8 2 P = Park 2. Engine Hour Display Indicator 4. Fuel Gauge - Check Engine Warning Indicator - NOTE: If the instrument cluster fails to illuminate, a battery over-voltage may have occurred and the instrument cluster may also occur under normal operation if the machine is at idle and high electrical load (lights, cooling fan, accessories) is...
Owners Manual
Page 51
... through the AWD coil (only on models with switchable AWD). Use the mode/reverse override button to the software version installed in the diagnostic mode, the wrench icon will also take the machine out of neutral or turn the key switch on . Set the park brake and shift the transmission to your ATV. Screen 1: Battery voltage Screen 2: Tachometer Screen 3: AWD diagnostic This gauge indicates whether...
... through the AWD coil (only on models with switchable AWD). Use the mode/reverse override button to the software version installed in the diagnostic mode, the wrench icon will also take the machine out of neutral or turn the key switch on . Set the park brake and shift the transmission to your ATV. Screen 1: Battery voltage Screen 2: Tachometer Screen 3: AWD diagnostic This gauge indicates whether...
Owners Manual
Page 54
...-recommended oil may cause serious engine damage. Fill the fuel tank with vehicle operation and handling. 4. Select an open area that allows room to maintain the level between the safe and add marks. 3. CAUTION 1. Drive slowly at full throttle or high speeds for the engine. See page 77. Perform regular checks on fluid levels, controls and areas outlined on your new Polaris ATV is...
...-recommended oil may cause serious engine damage. Fill the fuel tank with vehicle operation and handling. 4. Select an open area that allows room to maintain the level between the safe and add marks. 3. CAUTION 1. Drive slowly at full throttle or high speeds for the engine. See page 77. Perform regular checks on fluid levels, controls and areas outlined on your new Polaris ATV is...
Owners Manual
Page 58
... designed to extend belt life. 55 Cargo weight should be evenly distributed (1/3 on the front rack and 2/3 on the vehicle, and never exceed the weight capacities outlined in the specifications section of load. When operating over rough or hilly terrain, reduce speed and cargo weight to maintain stable driving conditions. Always read and understand the load distribution warning labels on the rear rack) and mounted as...
... designed to extend belt life. 55 Cargo weight should be evenly distributed (1/3 on the front rack and 2/3 on the vehicle, and never exceed the weight capacities outlined in the specifications section of load. When operating over rough or hilly terrain, reduce speed and cargo weight to maintain stable driving conditions. Always read and understand the load distribution warning labels on the rear rack) and mounted as...
Owners Manual
Page 75
... Headlight aim " More often under severe use, such as needed Check for leaks at tank cap, lines, fuel valve, filter, pump and carburetor; replace lines every two years Replace annually Inspect; clean Inspect Change every two years Inspect; replace as dirty or wet conditions L Emission Control System Service (California) J Dealer service item 72 Have an authorized Polaris dealer perform these services. adjust and lubricate if needed Clean out L Spark plug " Rear axle J Ignition Timing L J Fuel system L J Fuel filter...
... Headlight aim " More often under severe use, such as needed Check for leaks at tank cap, lines, fuel valve, filter, pump and carburetor; replace lines every two years Replace annually Inspect; clean Inspect Change every two years Inspect; replace as dirty or wet conditions L Emission Control System Service (California) J Dealer service item 72 Have an authorized Polaris dealer perform these services. adjust and lubricate if needed Clean out L Spark plug " Rear axle J Ignition Timing L J Fuel system L J Fuel filter...
Owners Manual
Page 95
Lower the vehicle to the wheel nut torque specifications chart. NOTE: All nuts that have a cotter pin installed must be serviced by your authorized Polaris dealer. 92 Place the transmission in PARK and lock the parking brake. 2. Torque the wheel nuts according to the ground. 5. Bolt Size Front 3/8″ Rear 3/8″ Sportsman 400/500 20 ft. Place the wheel on the wheel hub with the valve stem toward the outside and rotation...
Lower the vehicle to the wheel nut torque specifications chart. NOTE: All nuts that have a cotter pin installed must be serviced by your authorized Polaris dealer. 92 Place the transmission in PARK and lock the parking brake. 2. Torque the wheel nuts according to the ground. 5. Bolt Size Front 3/8″ Rear 3/8″ Sportsman 400/500 20 ft. Place the wheel on the wheel hub with the valve stem toward the outside and rotation...
Owners Manual
Page 110
... accessories such as hand held spot lights. If a high pressure system is with a garden hose and a pail of mild soap and water. Avoid the use of harsh cleaners since they can be waxed with a chamois 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. CAUTION 107 Polaris...
... accessories such as hand held spot lights. If a high pressure system is with a garden hose and a pail of mild soap and water. Avoid the use of harsh cleaners since they can be waxed with a chamois 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. CAUTION 107 Polaris...
Owners Manual
Page 119
... plugs or foreign material in mud or snow. in neutral, advance the throttle to engage clutch. times as described on an incline, use fast, brief, aggressive throttle application to about 1/8 throttle in high range. Starting out going up of clutch components. Driving at low RPM or Drive at low RPM/low ground speed. Poor engine performance. Slow and easy clutch engagement. When starting out on page 63. TROUBLESHOOTING Drive Belt and Cover Problems...
... plugs or foreign material in mud or snow. in neutral, advance the throttle to engage clutch. times as described on an incline, use fast, brief, aggressive throttle application to about 1/8 throttle in high range. Starting out going up of clutch components. Driving at low RPM or Drive at low RPM/low ground speed. Poor engine performance. Slow and easy clutch engagement. When starting out on page 63. TROUBLESHOOTING Drive Belt and Cover Problems...
Owners Manual
Page 123
SPECIFICATIONS SPORTSMAN 400 Gross Vehicle Weight Towing Capacity Hitch Tongue Capacity Front Rack Capacity Rear Rack Capacity Overall Length Overall Width Overall Height Wheelbase Ground Clearance Dry Weight Minimum Turning Radius Fuel Capacity Engine Oil Capacity Coolant Capacity Engine Displacement Bore x Stroke Pilot Jet Main Jet Needle Jet Jet Needle Pilot Screw Alternator Output Compression Ratio Carburetor Ignition System Ignition Timing Spark Plug / Gap Lubrication System Driving System Type 1200 lbs./544 kg 1225 lbs./556 kg 120 lbs./54 kg (Rear rack weight and tongue weight not to...
SPECIFICATIONS SPORTSMAN 400 Gross Vehicle Weight Towing Capacity Hitch Tongue Capacity Front Rack Capacity Rear Rack Capacity Overall Length Overall Width Overall Height Wheelbase Ground Clearance Dry Weight Minimum Turning Radius Fuel Capacity Engine Oil Capacity Coolant Capacity Engine Displacement Bore x Stroke Pilot Jet Main Jet Needle Jet Jet Needle Pilot Screw Alternator Output Compression Ratio Carburetor Ignition System Ignition Timing Spark Plug / Gap Lubrication System Driving System Type 1200 lbs./544 kg 1225 lbs./556 kg 120 lbs./54 kg (Rear rack weight and tongue weight not to...
Owners Manual
Page 125
SPECIFICATIONS SPORTSMAN 500 Gross Vehicle Weight Hitch Towing Rating Unbraked Trailer Towing Capacity* Hitch Tongue Capacity Front Rack Capacity Rear Rack Capacity Overall Length Overall Width Overall Height Wheelbase Ground Clearance Dry Weight Minimum Turning Radius Fuel Capacity Engine Oil Capacity Coolant Capacity Engine Displacement Bore x Stroke Pilot Jet Main Jet Needle Jet Jet Needle Pilot Screw Alternator Output Compression Ratio Carburetor Ignition System Ignition Timing Spark Plug / Gap Lubrication System Driving System Type 1200 lbs./544 kg 1225 lbs./556 kg 1786 lbs./810 kg 120 ...
SPECIFICATIONS SPORTSMAN 500 Gross Vehicle Weight Hitch Towing Rating Unbraked Trailer Towing Capacity* Hitch Tongue Capacity Front Rack Capacity Rear Rack Capacity Overall Length Overall Width Overall Height Wheelbase Ground Clearance Dry Weight Minimum Turning Radius Fuel Capacity Engine Oil Capacity Coolant Capacity Engine Displacement Bore x Stroke Pilot Jet Main Jet Needle Jet Jet Needle Pilot Screw Alternator Output Compression Ratio Carburetor Ignition System Ignition Timing Spark Plug / Gap Lubrication System Driving System Type 1200 lbs./544 kg 1225 lbs./556 kg 1786 lbs./810 kg 120 ...
Owners Manual
Page 129
SPECIFICATIONS SPORTSMAN 700 Gross Vehicle Weight Fuel Capacity Towing Rating 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 Main Jet Needle Jet Jet Needle Pilot Screw Alternator Output Compression Ratio Starting System Carburetor Ignition System Ignition Timing Spark Plug / Gap Lubrication System Driving System Type 1240 lbs./563 kg 4.25 gal./16 l 1500 lbs./681 ...
SPECIFICATIONS SPORTSMAN 700 Gross Vehicle Weight Fuel Capacity Towing Rating 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 Main Jet Needle Jet Jet Needle Pilot Screw Alternator Output Compression Ratio Starting System Carburetor Ignition System Ignition Timing Spark Plug / Gap Lubrication System Driving System Type 1240 lbs./563 kg 4.25 gal./16 l 1500 lbs./681 ...
Owners Manual
Page 134
... authorization for export. Vehicles importation rules vary considerably from Polaris Industries in your vehicle was purchased, Warranty or Service Bulletin repairs may be done by an authorized Polaris dealer. You may not give authorization for export from Polaris Industries. This policy does not apply to Safety Recalls. Exported Vehicles WARRANTY EXCEPT WHERE SPECIFICALLY REQUIRED BY LAW, THERE IS NO WARRANTY OR SERVICE BULLETIN COVERAGE ON...
... authorization for export. Vehicles importation rules vary considerably from Polaris Industries in your vehicle was purchased, Warranty or Service Bulletin repairs may be done by an authorized Polaris dealer. You may not give authorization for export from Polaris Industries. This policy does not apply to Safety Recalls. Exported Vehicles WARRANTY EXCEPT WHERE SPECIFICALLY REQUIRED BY LAW, THERE IS NO WARRANTY OR SERVICE BULLETIN COVERAGE ON...
Owners Manual
Page 136
... A Accessories ...107 ADJUSTMENTS ...112-114 Age Restrictions ...11 Air Filter Service ...93 All Wheel Drive ...44 Automatic Transmission ...43 Auxiliary Brake ...88 AWD ...44 E Electrical Switches ...EMISSION CONTROL SYSTEMS . . Engaging Front Gearcase ...Engine Cooling System ...Engine Stop Switch ...Equipment Modifications ...Exhaust Emission Control System ...36 68 44 86 36 15 68 B Battery ...104-106 Battery (Conventional) ...103 Battery Charging (Sealed) ...105-106 Battery Fluid (Conventional) ...105 Battery Installation ...104 Battery Removal ...104 Battery Storage ...105 Belt Life...
... A Accessories ...107 ADJUSTMENTS ...112-114 Age Restrictions ...11 Air Filter Service ...93 All Wheel Drive ...44 Automatic Transmission ...43 Auxiliary Brake ...88 AWD ...44 E Electrical Switches ...EMISSION CONTROL SYSTEMS . . Engaging Front Gearcase ...Engine Cooling System ...Engine Stop Switch ...Equipment Modifications ...Exhaust Emission Control System ...36 68 44 86 36 15 68 B Battery ...104-106 Battery (Conventional) ...103 Battery Charging (Sealed) ...105-106 Battery Fluid (Conventional) ...105 Battery Installation ...104 Battery Removal ...104 Battery Storage ...105 Belt Life...
Owners Manual
Page 137
... Spark Arrestor ...100 Spark Plug Removal/Replacement ...98 Spark Plugs ...98 SPECIFICATIONS ...120-127 Starting a Cold Engine ...53 Starting a Warm Engine ...54 Starting the Engine ...53-54 Steering Assembly ...89 Stop Switch ...36 Storage ...107-110 Storage Tips ...108-110 Switches ...36 N Noise Emission Control System ...68 O Odometer ...47 Oil Change ...78 Oil Change (400/500) ...78-79 Oil Change (600/700) ...80 Oil Check ...77 Oil Filter Change ...78 Oil, Front Gearcase ...82 Oil Pump Priming ...79 Oil, Rear Gearcase (600/700) ...84 Oil, Transmission (400/500) ...81 Oil, Transmission...
... Spark Arrestor ...100 Spark Plug Removal/Replacement ...98 Spark Plugs ...98 SPECIFICATIONS ...120-127 Starting a Cold Engine ...53 Starting a Warm Engine ...54 Starting the Engine ...53-54 Steering Assembly ...89 Stop Switch ...36 Storage ...107-110 Storage Tips ...108-110 Switches ...36 N Noise Emission Control System ...68 O Odometer ...47 Oil Change ...78 Oil Change (400/500) ...78-79 Oil Change (600/700) ...80 Oil Check ...77 Oil Filter Change ...78 Oil, Front Gearcase ...82 Oil Pump Priming ...79 Oil, Rear Gearcase (600/700) ...84 Oil, Transmission (400/500) ...81 Oil, Transmission...