Owners Manual
Page 12
... load extends over the side of losing control. at 0-3000 feet (5_ to 27_ C. S Clean pre-filter element often, more detailed loading information 7172748 SAFETY WARNING 7172566 ATTENTION S Operation of control resulting in dusty conditions. Overloading or carrying tall, off-center, or unsecured loads will severely damage the engine. See your risk of the rack. Consult owner's manual or dealer for braking when...
... load extends over the side of losing control. at 0-3000 feet (5_ to 27_ C. S Clean pre-filter element often, more detailed loading information 7172748 SAFETY WARNING 7172566 ATTENTION S Operation of control resulting in dusty conditions. Overloading or carrying tall, off-center, or unsecured loads will severely damage the engine. See your risk of the rack. Consult owner's manual or dealer for braking when...
Owners Manual
Page 20
... to) mowers, blades, tires, sprayers, or large racks, may increase the speed or power of tires specified for your ATV, and always maintain proper tire pressure. Allow a greater distance for carrying cargo or towing. Operator Safety SAFETY S Wet brakes may have been made to the vehicle, that may change the handling characteristics of accessories. When it's safe to proceed in this manual for braking. Cargo must be...
... to) mowers, blades, tires, sprayers, or large racks, may increase the speed or power of tires specified for your ATV, and always maintain proper tire pressure. Allow a greater distance for carrying cargo or towing. Operator Safety SAFETY S Wet brakes may have been made to the vehicle, that may change the handling characteristics of accessories. When it's safe to proceed in this manual for braking. Cargo must be...
Owners Manual
Page 42
... a minimum pump octane number of operation, or annually. OFF ON Fuel Tank The fuel tank filler cap (2) is located on page 50 for correct choke and throttle settings during starting. Choke CONTROLS 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 a cold engine. It has two positions: OFF: For vehicle storage and...
... a minimum pump octane number of operation, or annually. OFF ON Fuel Tank The fuel tank filler cap (2) is located on page 50 for correct choke and throttle settings during starting. Choke CONTROLS 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 a cold engine. It has two positions: OFF: For vehicle storage and...
Owners Manual
Page 43
CONTROLS Automatic Transmission Gear Selector The transmission gear selector (1) is located on your model. 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 the vehicle. Belt Life To extend belt life, use low forward gear in PARK and lock the parking brake. Apply the...
CONTROLS Automatic Transmission Gear Selector The transmission gear selector (1) is located on your model. 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 the vehicle. Belt Life To extend belt life, use low forward gear in PARK and lock the parking brake. Apply the...
Owners Manual
Page 44
... automatically engage any time the rear wheels lose traction. There is below 3100. Initially, the vehicle's electronic system will not enable the AWD until the engine RPM is no limit to the length of AWD in the instrument cluster will not disengage until the AWD switch is moving . Engage the AWD switch before switching to AWD while the rear wheels are spinning may be turned on or off while the vehicle...
... automatically engage any time the rear wheels lose traction. There is below 3100. Initially, the vehicle's electronic system will not enable the AWD until the engine RPM is no limit to the length of AWD in the instrument cluster will not disengage until the AWD switch is moving . Engage the AWD switch before switching to AWD while the rear wheels are spinning may be turned on or off while the vehicle...
Owners Manual
Page 46
... the fuel gauge show the level of the AWD system is enabled. 9 1 3. Refuel immediately. 8. Mode Indicator 43 Instrument Cluster Rider Information Center FEATURES The rider information center is located in the LCD, and the speedometer needle will blink. NOTE: If the instrument cluster fails to illuminate, a battery over-voltage may have shut off to protect the cluster's electrical system. Driving at idle and high electrical load (lights, cooling fan, accessories...
... the fuel gauge show the level of the AWD system is enabled. 9 1 3. Refuel immediately. 8. Mode Indicator 43 Instrument Cluster Rider Information Center FEATURES The rider information center is located in the LCD, and the speedometer needle will blink. NOTE: If the instrument cluster fails to illuminate, a battery over-voltage may have shut off to protect the cluster's electrical system. Driving at idle and high electrical load (lights, cooling fan, accessories...
Owners Manual
Page 48
... to neutral. 3. To leave the diagnostic mode, turn the key switch on . Turn the key switch off and on . 4. The initial screen display refers to your ATV. Screen 1: Battery voltage Screen 2: Tachometer Screen 3: AWD diagnostic This gauge indicates whether or not current is for all major repairs. Set the park brake and shift the transmission to toggle through the AWD coil (only on models with switchable AWD). Instrument Cluster Rider Information Center FEATURES...
... to neutral. 3. To leave the diagnostic mode, turn the key switch on . Turn the key switch off and on . 4. The initial screen display refers to your ATV. Screen 1: Battery voltage Screen 2: Tachometer Screen 3: AWD diagnostic This gauge indicates whether or not current is for all major repairs. Set the park brake and shift the transmission to toggle through the AWD coil (only on models with switchable AWD). Instrument Cluster Rider Information Center FEATURES...
Owners Manual
Page 51
.... See page 39. 2. Drive slowly at 20 hours, 200 miles, or one month, whichever comes first. 48 Perform the following the procedures for the engine. CAUTION Excessive heat build-up during the first three hours of a new engine will damage close-fitted engine parts. Vary the throttle positions. Fill the fuel tank with vehicle operation and handling. 4. Add oil if necessary to use...
.... See page 39. 2. Drive slowly at 20 hours, 200 miles, or one month, whichever comes first. 48 Perform the following the procedures for the engine. CAUTION Excessive heat build-up during the first three hours of a new engine will damage close-fitted engine parts. Vary the throttle positions. Fill the fuel tank with vehicle operation and handling. 4. Add oil if necessary to use...
Owners Manual
Page 55
... load distribution warning labels on the vehicle, and never exceed the weight capacities outlined in the specifications section of load. Do not obstruct the headlight beam with cargo. When operating over rough or hilly terrain, reduce speed and cargo weight to extend belt life. 52 Belt Life Use low forward gear when hauling or towing heavy cargo to maintain stable driving conditions. OPERATION Driving Safely Hauling...
... load distribution warning labels on the vehicle, and never exceed the weight capacities outlined in the specifications section of load. Do not obstruct the headlight beam with cargo. When operating over rough or hilly terrain, reduce speed and cargo weight to extend belt life. 52 Belt Life Use low forward gear when hauling or towing heavy cargo to maintain stable driving conditions. OPERATION Driving Safely Hauling...
Owners Manual
Page 56
... towing a load on one rack only increases the possibility of the vehicle and creates a less stable operating condition. Driving Safely Hauling Cargo OPERATION WARNING Hauling cargo improperly can create unstable operating conditions, which could result in loss of control of the vehicle. Always follow these precautions when hauling cargo: S REDUCE SPEED AND ALLOW GREATER DISTANCES FOR BRAKING WHEN HAULING CARGO. S CARGO WEIGHT...
... towing a load on one rack only increases the possibility of the vehicle and creates a less stable operating condition. Driving Safely Hauling Cargo OPERATION WARNING Hauling cargo improperly can create unstable operating conditions, which could result in loss of control of the vehicle. Always follow these precautions when hauling cargo: S REDUCE SPEED AND ALLOW GREATER DISTANCES FOR BRAKING WHEN HAULING CARGO. S CARGO WEIGHT...
Owners Manual
Page 71
... Control System Service (California) J Have an authorized Polaris dealer perform these procedures more often for leaks at one month Replace with oil change at tank cap, lines, fuel valve, filter, pump, carburetor; adjust; replace as needed Inspect coolant strength seasonally; 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 " Oil tank vent hose E (if equipped) E E J Valve clearance J Fuel system/filter " Radiator...
... Control System Service (California) J Have an authorized Polaris dealer perform these procedures more often for leaks at one month Replace with oil change at tank cap, lines, fuel valve, filter, pump, carburetor; adjust; replace as needed Inspect coolant strength seasonally; 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 " Oil tank vent hose E (if equipped) E E J Valve clearance J Fuel system/filter " Radiator...
Owners Manual
Page 107
... ATV Keeping your ATV is used, exercise extreme care to avoid water damage 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. NOTE: Grease all models. Avoid the use of a high pressure type car wash system for a while to clean your ATV clean will damage...
... ATV Keeping your ATV is used, exercise extreme care to avoid water damage 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. NOTE: Grease all models. Avoid the use of a high pressure type car wash system for a while to clean your ATV clean will damage...
Owners Manual
Page 117
... engine performance. Solution Shift transmission to low range during loading of Warm the engine at low RPM/low ground speed. Use low range only. TROUBLESHOOTING Drive Belt and Cover Problems Possible Cause Driving the ATV onto a pickup or tall trailer in mud or snow. Slow and easy clutch engagement. Towing/pushing at least 5 minutes. Utility use low range or dismount the ATV (after first applying the park brake) and perform...
... engine performance. Solution Shift transmission to low range during loading of Warm the engine at low RPM/low ground speed. Use low range only. TROUBLESHOOTING Drive Belt and Cover Problems Possible Cause Driving the ATV onto a pickup or tall trailer in mud or snow. Slow and easy clutch engagement. Towing/pushing at least 5 minutes. Utility use low range or dismount the ATV (after first applying the park brake) and perform...
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...
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...
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 132
... country to determine this vehicle's warranty or service bulletin coverage if you move to Polaris Industries in order to continue your vehicle was purchased, Warranty or Service Bulletin repairs may also be requested from the country of the selling dealer's authorized location. Dealers may be authorized to Safety Recalls. This policy does not apply to perform the warranty repair. If you have received...
... country to determine this vehicle's warranty or service bulletin coverage if you move to Polaris Industries in order to continue your vehicle was purchased, Warranty or Service Bulletin repairs may also be requested from the country of the selling dealer's authorized location. Dealers may be authorized to Safety Recalls. This policy does not apply to perform the warranty repair. If you have received...
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...
... 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...