Owners Manual
Page 12
... (5_ to the racks. Safety Decals and Locations WARNING IMPROPER TIRE PRESSURE OR OVERLOADING can cause engine damage. 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). Loads should be centered, carried as low as possible, and firmly secured to 27_ C. Consult owner's manual or dealer for braking when carrying cargo. at...
... (5_ to the racks. Safety Decals and Locations WARNING IMPROPER TIRE PRESSURE OR OVERLOADING can cause engine damage. 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). Loads should be centered, carried as low as possible, and firmly secured to 27_ C. Consult owner's manual or dealer for braking when carrying cargo. at...
Owners Manual
Page 14
...: VIN: ALL WHEEL DRIVE SWITCH Do not push switch to engage AWD if the rear wheels are spinning. 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. See your Owner's Manual. 7079780 THIS VEHICLE IS AN ALL TERRAIN VEHICLE AND IS NOT INTENDED FOR USE ON PUBLIC ROADS. Safety Decals...
...: VIN: ALL WHEEL DRIVE SWITCH Do not push switch to engage AWD if the rear wheels are spinning. 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. See your Owner's Manual. 7079780 THIS VEHICLE IS AN ALL TERRAIN VEHICLE AND IS NOT INTENDED FOR USE ON PUBLIC ROADS. Safety Decals...
Owners Manual
Page 20
... warranty on your Polaris ATV is terminated if any equipment has been added to the vehicle, or if any equipment that increase its speed or power. Reduce speed and follow the instructions in reverse. Allow a greater distance for carrying cargo or towing. Any modifications to the vehicle for your ATV, and always maintain proper tire pressure. Operator Safety SAFETY S Wet brakes may change the handling...
... warranty on your Polaris ATV is terminated if any equipment has been added to the vehicle, or if any equipment that increase its speed or power. Reduce speed and follow the instructions in reverse. Allow a greater distance for carrying cargo or towing. Any modifications to the vehicle for your ATV, and always maintain proper tire pressure. Operator Safety SAFETY S Wet brakes may change the handling...
Owners Manual
Page 42
Choke CONTROLS The choke assists in -line fuel filter should be replaced by your dealer after every 100 hours of operation, or annually. ON: For normal operation. Fuel Valve The fuel valve (1) is located directly below the handlebar. Use either leaded or unleaded gasoline with a minimum pump octane number of 87=(R+ M/2) octane. 2 1 Fuel Filter The in starting a cold engine. OFF ON Fuel Tank The fuel tank filler cap (2) is located...
Choke CONTROLS The choke assists in -line fuel filter should be replaced by your dealer after every 100 hours of operation, or annually. ON: For normal operation. Fuel Valve The fuel valve (1) is located directly below the handlebar. Use either leaded or unleaded gasoline with a minimum pump octane number of 87=(R+ M/2) octane. 2 1 Fuel Filter The in starting a cold engine. OFF ON Fuel Tank The fuel tank filler cap (2) is located...
Owners Manual
Page 43
... Shifting gears with the engine idling, move the lever to activate the high/park lock-out mechanism. Belt Life To extend belt life, use low forward gear in PARK and lock the parking brake. Apply the auxiliary brake if shifting into HIGH or PARK, you must first apply the auxiliary brake to the desired gear. To change gears, stop the vehicle, and with the engine speed above idle or while the vehicle is located on your model. Shift...
... Shifting gears with the engine idling, move the lever to activate the high/park lock-out mechanism. Belt Life To extend belt life, use low forward gear in PARK and lock the parking brake. Apply the auxiliary brake if shifting into HIGH or PARK, you must first apply the auxiliary brake to the desired gear. To change gears, stop the vehicle, and with the engine speed above idle or while the vehicle is located on your model. Shift...
Owners Manual
Page 44
... instrument cluster will be turned on or off while the vehicle is moving , it will not enable the AWD until the AWD switch is below 3100. Always switch to AWD while the rear wheels are spinning, release the throttle before getting into conditions where front wheel drive may be on the right handlebar. CAUTION Switching to AWD while the rear wheels have traction or are equipped with a unique, Polaris-exclusive, All Wheel Drive (AWD...
... instrument cluster will be turned on or off while the vehicle is moving , it will not enable the AWD until the AWD switch is below 3100. Always switch to AWD while the rear wheels are spinning, release the throttle before getting into conditions where front wheel drive may be on the right handlebar. CAUTION Switching to AWD while the rear wheels have traction or are equipped with a unique, Polaris-exclusive, All Wheel Drive (AWD...
Owners Manual
Page 46
... HOT will usually clear the warning. 6. Gear Indicator - Fuel Gauge - The segments of the fuel gauge show the level of the AWD system is applied. All segments will flash, "FUEL" will display in the fuel tank. Engine Hour Display Indicator 4. This warning usually indicates that the ATV is being operated at idle and high electrical load (lights, cooling fan, accessories) is enabled. 9 1 3. Driving at start-up for proper diagnosis. 1. This...
... HOT will usually clear the warning. 6. Gear Indicator - Fuel Gauge - The segments of the fuel gauge show the level of the AWD system is applied. All segments will flash, "FUEL" will display in the fuel tank. Engine Hour Display Indicator 4. This warning usually indicates that the ATV is being operated at idle and high electrical load (lights, cooling fan, accessories) is enabled. 9 1 3. Driving at start-up for proper diagnosis. 1. This...
Owners Manual
Page 48
... the park brake and shift the transmission to your ATV. To leave the diagnostic mode, turn the key switch on . Hold the mode/reverse override button and turn the key switch off and wait 10 seconds. 2. Please return your ATV to neutral. 3. Instrument Cluster Rider Information Center FEATURES Diagnostic Mode The diagnostic mode is for all major repairs. Screen 1: Battery voltage Screen 2: Tachometer Screen 3: AWD diagnostic This gauge indicates...
... the park brake and shift the transmission to your ATV. To leave the diagnostic mode, turn the key switch on . Hold the mode/reverse override button and turn the key switch off and wait 10 seconds. 2. Please return your ATV to neutral. 3. Instrument Cluster Rider Information Center FEATURES Diagnostic Mode The diagnostic mode is for all major repairs. Screen 1: Battery voltage Screen 2: Tachometer Screen 3: AWD diagnostic This gauge indicates...
Owners Manual
Page 51
...oil reservoir level on your new Polaris ATV is as important as the first ten hours of operation, or the time it takes to use the first two full tanks of a new engine will damage close-fitted engine parts. Drive slowly at sustained idle. 5. We recommend the use . Fill the fuel tank with vehicle operation and handling. 4. Pull only light...oil may cause serious engine damage. Perform regular checks on fluid levels, controls and areas outlined on the daily pre-ride inspection checklist. During the break-in period, change both the oil and the filter at full throttle or high speeds ...
...oil reservoir level on your new Polaris ATV is as important as the first ten hours of operation, or the time it takes to use the first two full tanks of a new engine will damage close-fitted engine parts. Drive slowly at sustained idle. 5. We recommend the use . Fill the fuel tank with vehicle operation and handling. 4. Pull only light...oil may cause serious engine damage. Perform regular checks on fluid levels, controls and areas outlined on the daily pre-ride inspection checklist. During the break-in period, change both the oil and the filter at full throttle or high speeds ...
Owners Manual
Page 55
... the load distribution warning labels on the vehicle, and never exceed the weight capacities outlined in the specifications section of load. Belt Life Use low forward gear when hauling or towing heavy cargo to maintain stable driving conditions. Do not obstruct the headlight beam with cargo. Cargo weight should be evenly distributed (1/3 on the front rack and 2/3 on the rear rack) and mounted as low as...
... the load distribution warning labels on the vehicle, and never exceed the weight capacities outlined in the specifications section of load. Belt Life Use low forward gear when hauling or towing heavy cargo to maintain stable driving conditions. Do not obstruct the headlight beam with cargo. Cargo weight should be evenly distributed (1/3 on the front rack and 2/3 on the rear rack) and mounted as low as...
Owners Manual
Page 70
... needed J Steering " Front suspension " Rear suspension Make adjustments j as needed See Pre ed. change yearly Inspect; Tires " Brake fluid level " Brake lever travel Brake system Wheels/fasteners Frame fasteners " Engine oil level E E " Air filter, pre-filter " Air box sediment E tube Coolant Headlamp/tail lamp/worklight " Air filter, E main element Recoil housing " Brake pad wear J Battery " Front gearcase oil " Rear gearcase oil (if equipped) " Transmission oil " Engine breather E filter (if equipped) " Perform these services. 67 Periodic Maintenance Chart Item...
... needed J Steering " Front suspension " Rear suspension Make adjustments j as needed See Pre ed. change yearly Inspect; Tires " Brake fluid level " Brake lever travel Brake system Wheels/fasteners Frame fasteners " Engine oil level E E " Air filter, pre-filter " Air box sediment E tube Coolant Headlamp/tail lamp/worklight " Air filter, E main element Recoil housing " Brake pad wear J Battery " Front gearcase oil " Rear gearcase oil (if equipped) " Transmission oil " Engine breather E filter (if equipped) " Perform these services. 67 Periodic Maintenance Chart Item...
Owners Manual
Page 71
..." Cooling hoses " Engine mounts Exhaust muffler/ pipe " Perform these services. 68 clean external surfaces Inspect for leaks Inspect Inspect J Throttle Cable/ E ETC Switch J Choke cable E E Carburetor air intake ducts/ flange Drive belt Cooling system " Engine oil change E E " Oil filter change Inspect routing, condition Inspect; replace lines every two years Inspect; E Emission Control System Service (California) J Have an authorized Polaris dealer perform these procedures more often for vehicles subjected to storage Inspect; MAINTENANCE AND LUBRICATION Periodic Maintenance...
..." Cooling hoses " Engine mounts Exhaust muffler/ pipe " Perform these services. 68 clean external surfaces Inspect for leaks Inspect Inspect J Throttle Cable/ E ETC Switch J Choke cable E E Carburetor air intake ducts/ flange Drive belt Cooling system " Engine oil change E E " Oil filter change Inspect routing, condition Inspect; replace lines every two years Inspect; E Emission Control System Service (California) J Have an authorized Polaris dealer perform these procedures more often for vehicles subjected to storage Inspect; MAINTENANCE AND LUBRICATION Periodic Maintenance...
Owners Manual
Page 107
... a garden hose and a pail of Polaris products. NOTE: If warning and safety labels are available for free replacement. NOTE: Grease all models. Avoid the use of harsh cleaners since they can be waxed with any water that may have entered the engine or exhaust system. Washing the ATV The best and safest way to the wheel bearings, transmission seals, body panels, brakes and warning labels. See...
... a garden hose and a pail of Polaris products. NOTE: If warning and safety labels are available for free replacement. NOTE: Grease all models. Avoid the use of harsh cleaners since they can be waxed with any water that may have entered the engine or exhaust system. Washing the ATV The best and safest way to the wheel bearings, transmission seals, body panels, brakes and warning labels. See...
Owners Manual
Page 117
.... Towing/pushing at least 5 minutes. Clutch malfunction. Starting out going up of the ATV to engage clutch. TROUBLESHOOTING Drive Belt and Cover Problems Possible Cause Driving the ATV onto a pickup or tall trailer in gas tank, fuel lines, or carburetor. Use low range only. Belt slippage from a stopped position. short bursts, 5 to neutral. Solution Shift transmission to low range during loading of Warm the engine at low RPM/low ground speed. times...
.... Towing/pushing at least 5 minutes. Clutch malfunction. Starting out going up of the ATV to engage clutch. TROUBLESHOOTING Drive Belt and Cover Problems Possible Cause Driving the ATV onto a pickup or tall trailer in gas tank, fuel lines, or carburetor. Use low range only. Belt slippage from a stopped position. short bursts, 5 to neutral. Solution Shift transmission to low range during loading of Warm the engine at low RPM/low ground speed. times...
Owners Manual
Page 121
SPECIFICATIONS SPORTSMAN 400 Gross Vehicle Weight Towing Capacity Hitch Tongue Capacity Front Rack/Storage Box Capacity Rear Rack/Storage Box 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...
SPECIFICATIONS SPORTSMAN 400 Gross Vehicle Weight Towing Capacity Hitch Tongue Capacity Front Rack/Storage Box Capacity Rear Rack/Storage Box 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...
Owners Manual
Page 123
SPECIFICATIONS SPORTSMAN 500 Gross Vehicle Weight Towing Rating Unbraked Trailer Towing Capacity* Hitch Tongue Capacity Front Rack/Storage Box Capacity Rear Rack/Storage Box 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 ...
SPECIFICATIONS SPORTSMAN 500 Gross Vehicle Weight Towing Rating Unbraked Trailer Towing Capacity* Hitch Tongue Capacity Front Rack/Storage Box Capacity Rear Rack/Storage Box 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 ...
Owners Manual
Page 125
SPECIFICATIONS SPORTSMAN 600 Gross Vehicle Weight Fuel Capacity 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 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 kg 150 lbs./68...
SPECIFICATIONS SPORTSMAN 600 Gross Vehicle Weight Fuel Capacity 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 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 kg 150 lbs./68...
Owners Manual
Page 127
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
... Filter ...90 F FEATURES ...41-46 Filter Systems ...90 Footwell Removal ...87 Front Gearcase Oil ...79 Front Wheel Hub Tightening ...88 Fuel Filter ...39 Fuel Safety ...47 Fuel Tank ...39 Fuel Valve ...39 C Camber and Caster ...109 Carburetor/Idle RPM ...110 Choke ...39 Chrome Wheel Care ...108 Cleaning ...104-107 Clutching Charts (Sportsman 400) ...119 (Sportsman 500) ...121 (Sportsman 600) ...123 (Sportsman 700) ...125 Cold Weather Operation ...51 CONTROLS ...33-40 Coolant Level ...83 Cooling System ...83 Cooling...
... Filter ...90 F FEATURES ...41-46 Filter Systems ...90 Footwell Removal ...87 Front Gearcase Oil ...79 Front Wheel Hub Tightening ...88 Fuel Filter ...39 Fuel Safety ...47 Fuel Tank ...39 Fuel Valve ...39 C Camber and Caster ...109 Carburetor/Idle RPM ...110 Choke ...39 Chrome Wheel Care ...108 Cleaning ...104-107 Clutching Charts (Sportsman 400) ...119 (Sportsman 500) ...121 (Sportsman 600) ...123 (Sportsman 700) ...125 Cold Weather Operation ...51 CONTROLS ...33-40 Coolant Level ...83 Cooling System ...83 Cooling...
Owners Manual
Page 135
... SPECIFICATIONS ...118-125 Starting a Cold Engine ...50 Starting a Warm Engine ...51 Steering Assembly ...86 Stop Switch ...33 Storage ...104-107 Storage Tips ...105-107 Switches ...33 L Light Switches ...35 Lights ...91-94 Low Beam Adjustment ...92 Low Range ...98 Lubrication Guide ...71 M Main Switch ...33 MAINTENANCE AND LUBRICATION ...66-108 Maintenance Record ...70 Making Turns ...55 Master Cylinder ...36 Mode/Reverse Override Switch ...33 N Noise Emission Control System ...65 O Odometer ...44 Oil Change ...74 Oil Change (Sportsman 400...
... SPECIFICATIONS ...118-125 Starting a Cold Engine ...50 Starting a Warm Engine ...51 Steering Assembly ...86 Stop Switch ...33 Storage ...104-107 Storage Tips ...105-107 Switches ...33 L Light Switches ...35 Lights ...91-94 Low Beam Adjustment ...92 Low Range ...98 Lubrication Guide ...71 M Main Switch ...33 MAINTENANCE AND LUBRICATION ...66-108 Maintenance Record ...70 Making Turns ...55 Master Cylinder ...36 Mode/Reverse Override Switch ...33 N Noise Emission Control System ...65 O Odometer ...44 Oil Change ...74 Oil Change (Sportsman 400...