Owners Manual
Page 12
... if load extends over the side of losing control. Do not operate vehicle without the air filter element will increase your Owner's Manual. Overloading or carrying tall, off-center, or unsecured loads will severely damage the engine. For stability on temperature and altitude. Do not block headlight. Consult owner's manual or dealer for braking when carrying cargo. Factory setting: 40_ to the racks. See your...
... if load extends over the side of losing control. Do not operate vehicle without the air filter element will increase your Owner's Manual. Overloading or carrying tall, off-center, or unsecured loads will severely damage the engine. For stability on temperature and altitude. Do not block headlight. Consult owner's manual or dealer for braking when carrying cargo. Factory setting: 40_ to the racks. See your...
Owners Manual
Page 14
... sudden increases in AWD. INC. Loss of control or forward flipover may cause severe drive shaft and clutch damage. DATE: VIN: ALL WHEEL DRIVE SWITCH Do not push switch to engage AWD if the rear wheels are spinning. See Owner's Manual. 7172564 SAFETY MANUFACTURED BY: POLARIS IND. This may result, especially in power and traction if too much throttle is applied. VERTICAL WEIGHT: 150 LBS. (68KG) 7170509 Sportsman 600/700 11
... sudden increases in AWD. INC. Loss of control or forward flipover may cause severe drive shaft and clutch damage. DATE: VIN: ALL WHEEL DRIVE SWITCH Do not push switch to engage AWD if the rear wheels are spinning. See Owner's Manual. 7172564 SAFETY MANUFACTURED BY: POLARIS IND. This may result, especially in power and traction if too much throttle is applied. VERTICAL WEIGHT: 150 LBS. (68KG) 7170509 Sportsman 600/700 11
Owners Manual
Page 20
... carrying cargo or towing. S Never modify an ATV through improper installation or use the size and type of accessories. Test the brakes after leaving water. Reduce speed and follow the instructions in this manual for braking. The warranty on your ATV, and always maintain proper tire pressure. When it's safe to ) mowers, blades, tires, sprayers, or large racks, may change the handling characteristics of our...
... carrying cargo or towing. S Never modify an ATV through improper installation or use the size and type of accessories. Test the brakes after leaving water. Reduce speed and follow the instructions in this manual for braking. The warranty on your ATV, and always maintain proper tire pressure. When it's safe to ) mowers, blades, tires, sprayers, or large racks, may change the handling characteristics of our...
Owners Manual
Page 42
.... It has two positions: OFF: For vehicle storage and when transporting. Do not attempt to the engine starting procedure on the left side panel. OFF ON Fuel Tank The fuel tank filler cap (2) is located on page 50 for correct choke and throttle settings during starting a cold engine. Choke CONTROLS The choke assists in -line fuel filter should be replaced by your dealer after every 100 hours...
.... It has two positions: OFF: For vehicle storage and when transporting. Do not attempt to the engine starting procedure on the left side panel. OFF ON Fuel Tank The fuel tank filler cap (2) is located on page 50 for correct choke and throttle settings during starting a cold engine. Choke CONTROLS The choke assists in -line fuel filter should be replaced by your dealer after every 100 hours...
Owners Manual
Page 43
... extend belt life, use low forward gear in PARK and lock the parking brake. Shift patterns vary, depending on the right side of time. 40 To change gears, stop the vehicle, and with the engine idling, move the lever to apply the brake. 1 H L N R P CAUTION Shifting gears with the engine speed above idle or while the vehicle is moving could cause transmission damage. CONTROLS Automatic Transmission Gear Selector The transmission gear selector (1) is located on your model. H: High Gear L: Low Gear N: Neutral R: Reverse P: Park...
... extend belt life, use low forward gear in PARK and lock the parking brake. Shift patterns vary, depending on the right side of time. 40 To change gears, stop the vehicle, and with the engine idling, move the lever to apply the brake. 1 H L N R P CAUTION Shifting gears with the engine speed above idle or while the vehicle is moving could cause transmission damage. CONTROLS Automatic Transmission Gear Selector The transmission gear selector (1) is located on your model. H: High Gear L: Low Gear N: Neutral R: Reverse P: Park...
Owners Manual
Page 44
... FEATURES Polaris 4-wheel drive ATVs are at all 1 times. When in AWD, the front gearcase will automatically disengage. See page 33. Initially, the vehicle's electronic system will not disengage until the rear wheels regain traction. If the switch is in AWD and the AWD indicator light in 2 wheel drive at rest. 41 CAUTION Switching to AWD. Engage the AWD switch before switching to AWD while the rear wheels are spinning, release the throttle before getting into conditions...
... FEATURES Polaris 4-wheel drive ATVs are at all 1 times. When in AWD, the front gearcase will automatically disengage. See page 33. Initially, the vehicle's electronic system will not disengage until the rear wheels regain traction. If the switch is in AWD and the AWD indicator light in 2 wheel drive at rest. 41 CAUTION Switching to AWD. Engage the AWD switch before switching to AWD while the rear wheels are spinning, release the throttle before getting into conditions...
Owners Manual
Page 46
... is at idle and high electrical load (lights, cooling fan, accessories) is applied. Driving at a higher RPM or connecting a battery charger will light up for 2.5 seconds at an RPM too low to your Polaris dealer for proper diagnosis. 1. Check Engine Warning Indicator - Mode Indicator 43 Gear Indicator - This indicator illuminates when the electrical portion of fuel in : 4 5 6 3 H = High Range 7 L = Low Range N = Neutral R = Reverse 8 2 P = Park 2. As the shift lever...
... is at idle and high electrical load (lights, cooling fan, accessories) is applied. Driving at a higher RPM or connecting a battery charger will light up for 2.5 seconds at an RPM too low to your Polaris dealer for proper diagnosis. 1. Check Engine Warning Indicator - Mode Indicator 43 Gear Indicator - This indicator illuminates when the electrical portion of fuel in : 4 5 6 3 H = High Range 7 L = Low Range N = Neutral R = Reverse 8 2 P = Park 2. As the shift lever...
Owners Manual
Page 48
... key switch on models with switchable AWD). Set the park brake and shift the transmission to toggle through the AWD coil (only on . 4. NOTE: Any movement of the tires will remain lit. The initial screen display refers to your ATV. Turn the key switch off and on. Screen 4: Gear circuit diagnostic This screen displays the resistance value (in your dealer for informational purposes only. Instrument Cluster Rider Information Center FEATURES...
... key switch on models with switchable AWD). Set the park brake and shift the transmission to toggle through the AWD coil (only on . 4. NOTE: Any movement of the tires will remain lit. The initial screen display refers to your ATV. Turn the key switch off and on. Screen 4: Gear circuit diagnostic This screen displays the resistance value (in your dealer for informational purposes only. Instrument Cluster Rider Information Center FEATURES...
Owners Manual
Page 51
... serious engine damage. Add oil if necessary to use the first two full tanks of use of operation will result in . Select an open area that allows room to familiarize yourself with gasoline. See page 49. 6. Pull only light loads. 7. During the break-in period, change both the oil and the filter at full throttle or high speeds for extended...
... serious engine damage. Add oil if necessary to use the first two full tanks of use of operation will result in . Select an open area that allows room to familiarize yourself with gasoline. See page 49. 6. Pull only light loads. 7. During the break-in period, change both the oil and the filter at full throttle or high speeds for extended...
Owners Manual
Page 55
... load distribution warning labels 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 extend belt life. 52 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. OPERATION Driving Safely Hauling...
... load distribution warning labels 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 extend belt life. 52 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. OPERATION Driving Safely Hauling...
Owners Manual
Page 56
... alter vehicle handling and may require backing downhill. Always attach the tow load to overturn. S HEAVY LOADS CAN CAUSE BRAKING AND CONTROL PROBLEMS. Use extreme caution when applying brakes with extra caution. S USE EXTREME CAUTION when operating with loads that extend over rough or hilly terrain, reduce speed and cargo to maintain stable driving conditions. Carrying loads high on the rear rack. S OPERATE...
... alter vehicle handling and may require backing downhill. Always attach the tow load to overturn. S HEAVY LOADS CAN CAUSE BRAKING AND CONTROL PROBLEMS. Use extreme caution when applying brakes with extra caution. S USE EXTREME CAUTION when operating with loads that extend over rough or hilly terrain, reduce speed and cargo to maintain stable driving conditions. Carrying loads high on the rear rack. S OPERATE...
Owners Manual
Page 71
... Control System Service (California) J Have an authorized Polaris dealer perform these procedures more often 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 at tank cap, lines, fuel valve, filter, pump, carburetor; replace lines every two years Inspect; clean external surfaces Inspect for vehicles subjected to storage Inspect; Drain bowl periodically and prior to severe use. adjust; replace as needed Inspect coolant...
... Control System Service (California) J Have an authorized Polaris dealer perform these procedures more often 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 at tank cap, lines, fuel valve, filter, pump, carburetor; replace lines every two years Inspect; clean external surfaces Inspect for vehicles subjected to storage Inspect; Drain bowl periodically and prior to severe use. adjust; replace as needed Inspect coolant...
Owners Manual
Page 107
... run for all models. Avoid the use of additional accessories available for washing the ATV. Accessory outlets are damaged, contact your ATV. NOTE: Grease all zerk fittings immediately after washing, and allow the vehicle to prevent water spots. Rinse with water frequently and dry with a garden hose and a pail of Polaris products. Polaris also has a wide range of a high pressure type car...
... run for all models. Avoid the use of additional accessories available for washing the ATV. Accessory outlets are damaged, contact your ATV. NOTE: Grease all zerk fittings immediately after washing, and allow the vehicle to prevent water spots. Rinse with water frequently and dry with a garden hose and a pail of Polaris products. Polaris also has a wide range of a high pressure type car...
Owners Manual
Page 117
... of control and vehicle overturn. Climbing over large objects from water Shift the transmission to engage clutch. Contact your dealer for service. 114 Stuck in high range. WARNING: Excessive throttle may cause loss of clutch components. TROUBLESHOOTING Drive Belt and Cover Problems Possible Cause Driving the ATV onto a pickup or tall trailer in mud or snow. low ground speed (at The use fast, aggressive throttle application to about 1/8 throttle in neutral, advance the throttle...
... of control and vehicle overturn. Climbing over large objects from water Shift the transmission to engage clutch. Contact your dealer for service. 114 Stuck in high range. WARNING: Excessive throttle may cause loss of clutch components. TROUBLESHOOTING Drive Belt and Cover Problems Possible Cause Driving the ATV onto a pickup or tall trailer in mud or snow. low ground speed (at The use fast, aggressive throttle application to about 1/8 throttle in neutral, advance the throttle...
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./68.1 kg...
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./68.1 kg...
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
...-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 400/500) ...74-76 (Sportsman 600/700) ...77 Oil Check ...73 Oil Filter Change ...74 Oil Pump Priming ...76 OPERATION ...47-64 Operator Safety ...13-32 T TABLE OF CONTENTS ...5 Tachometer ...44 Taillight ...94 Throttle Cable Freeplay ...111 Throttle Lever ...34 Tires ...88 Toe Alignment ...86 Transmission Oil (Sportsman...
...-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 400/500) ...74-76 (Sportsman 600/700) ...77 Oil Check ...73 Oil Filter Change ...74 Oil Pump Priming ...76 OPERATION ...47-64 Operator Safety ...13-32 T TABLE OF CONTENTS ...5 Tachometer ...44 Taillight ...94 Throttle Cable Freeplay ...111 Throttle Lever ...34 Tires ...88 Toe Alignment ...86 Transmission Oil (Sportsman...