Owners Manual
Page 10
... speed and cargo. Loads should be centered, carried as low as possible, and firmly secured to 80_ F. Safety Decals and Locations WARNING IMPROPER TIRE PRESSURE OR OVERLOADING can cause engine damage. With dual racks, load distribution 1/3 front 2/3 rear is best. Be careful if load extends over the side of control resulting in dusty conditions. TIRE PRESSURE IN PSI (KPa): FRONT 5 (34,5) REAR 5 (34,5) MAXIMUM WEIGHT CAPACITY (Gross Vehicle Weight...
... speed and cargo. Loads should be centered, carried as low as possible, and firmly secured to 80_ F. Safety Decals and Locations WARNING IMPROPER TIRE PRESSURE OR OVERLOADING can cause engine damage. With dual racks, load distribution 1/3 front 2/3 rear is best. Be careful if load extends over the side of control resulting in dusty conditions. TIRE PRESSURE IN PSI (KPa): FRONT 5 (34,5) REAR 5 (34,5) MAXIMUM WEIGHT CAPACITY (Gross Vehicle Weight...
Owners Manual
Page 12
... HITCH MAX. DATE: VIN: ALL WHEEL DRIVE SWITCH Do not push switch to engage AWD if the rear wheels are spinning. This may result, especially in power and traction if too much throttle is applied. Safety Decals and Locations WARNING Pushing reverse override button may cause sudden increases in AWD. VERTICAL WEIGHT: 120 LBS. (55KG) 7170911 Sportsman 450/500 TRAILER MAX WEIGHT: 1500 LBS. (682 KG) ON LEVEL GROUND...
... HITCH MAX. DATE: VIN: ALL WHEEL DRIVE SWITCH Do not push switch to engage AWD if the rear wheels are spinning. This may result, especially in power and traction if too much throttle is applied. Safety Decals and Locations WARNING Pushing reverse override button may cause sudden increases in AWD. VERTICAL WEIGHT: 120 LBS. (55KG) 7170911 Sportsman 450/500 TRAILER MAX WEIGHT: 1500 LBS. (682 KG) ON LEVEL GROUND...
Owners Manual
Page 18
... use the size and type of tires specified for carrying cargo or towing. Equipment Modifications We are concerned for the safety of our customers and for braking. Any modifications to dry out the pads. NOTE: The addition of certain accessories, including (but not limited to) mowers, blades, tires, sprayers, or large racks, may increase the speed or power of the vehicle, or...
... use the size and type of tires specified for carrying cargo or towing. Equipment Modifications We are concerned for the safety of our customers and for braking. Any modifications to dry out the pads. NOTE: The addition of certain accessories, including (but not limited to) mowers, blades, tires, sprayers, or large racks, may increase the speed or power of the vehicle, or...
Owners Manual
Page 40
... engine starting procedure on the bottom of the fuel tank. Refer to clean the fuel filter. 37 Fuel Valve The fuel valve (1) is located on page 48 for correct choke and throttle settings during starting a cold engine. Refuel when the gauge indicates a low fuel condition. 2 Fuel Tank The fuel tank filler cap (2) is equipped with a minimum pump octane number of 87=(R+ M/2) octane. Access the fuel valve through the right front wheel well. RES 1 Fuel Filter The in starting . Choke CONTROLS...
... engine starting procedure on the bottom of the fuel tank. Refer to clean the fuel filter. 37 Fuel Valve The fuel valve (1) is located on page 48 for correct choke and throttle settings during starting a cold engine. Refuel when the gauge indicates a low fuel condition. 2 Fuel Tank The fuel tank filler cap (2) is equipped with a minimum pump octane number of 87=(R+ M/2) octane. Access the fuel valve through the right front wheel well. RES 1 Fuel Filter The in starting . Choke CONTROLS...
Owners Manual
Page 41
... 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. Whenever the ATV is moving could cause transmission damage. H: High Gear L: Low Gear N: Neutral R: Reverse P: Park 1 H L N R P CAUTION Shifting gears with the engine idling, move...
... 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. Whenever the ATV is moving could cause transmission damage. H: High Gear L: Low Gear N: Neutral R: Reverse P: Park 1 H L N R P CAUTION Shifting gears with the engine idling, move...
Owners Manual
Page 42
... rear wheels are spinning, release the throttle before getting into conditions where front wheel drive may be needed. When in AWD. Engage the AWD switch before switching to AWD while the rear wheels are at all wheel drive and the AWD indicator light in all times. Always switch to the length of AWD in two-wheel drive at rest. 39 When the switch is on 2X4, the ATV is in the instrument cluster will not enable the AWD...
... rear wheels are spinning, release the throttle before getting into conditions where front wheel drive may be needed. When in AWD. Engage the AWD switch before switching to AWD while the rear wheels are at all wheel drive and the AWD indicator light in all times. Always switch to the length of AWD in two-wheel drive at rest. 39 When the switch is on 2X4, the ATV is in the instrument cluster will not enable the AWD...
Owners Manual
Page 44
..., "FUEL" will light up . All segments will display in the fuel tank. Service Interval/Diagnostic Mode Indicator 5. 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. Driving at start-up for proper diagnosis. 1. Instrument Cluster Rider Information Center FEATURES The rider information center is activated. Check Engine Warning Indicator - If this occurs, take the ATV to keep the battery charged...
..., "FUEL" will light up . All segments will display in the fuel tank. Service Interval/Diagnostic Mode Indicator 5. 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. Driving at start-up for proper diagnosis. 1. Instrument Cluster Rider Information Center FEATURES The rider information center is activated. Check Engine Warning Indicator - If this occurs, take the ATV to keep the battery charged...
Owners Manual
Page 46
... the gear switch input of the tires will remain lit. The initial screen display refers to your ATV. To leave the diagnostic mode, turn the key switch on models with switchable AWD). Use the mode/reverse override button to neutral. 3. Instrument Cluster Rider Information Center FEATURES Diagnostic Mode The diagnostic mode is for all major repairs. Set the park brake and shift the transmission to toggle through the AWD coil...
... the gear switch input of the tires will remain lit. The initial screen display refers to your ATV. To leave the diagnostic mode, turn the key switch on models with switchable AWD). Use the mode/reverse override button to neutral. 3. Instrument Cluster Rider Information Center FEATURES Diagnostic Mode The diagnostic mode is for all major repairs. Set the park brake and shift the transmission to toggle through the AWD coil...
Owners Manual
Page 49
... in the clutches and belt by operating at slower speeds during the first three hours of operation will damage close-fitted engine parts and drive components. Pull only light loads. See page 70. Perform regular checks on fluid levels, controls and areas outlined on the dipstick. Engine and Drivetrain Break-in period, change both the oil and the filter at sustained idle. 5. During the...
... in the clutches and belt by operating at slower speeds during the first three hours of operation will damage close-fitted engine parts and drive components. Pull only light loads. See page 70. Perform regular checks on fluid levels, controls and areas outlined on the dipstick. Engine and Drivetrain Break-in period, change both the oil and the filter at sustained idle. 5. During the...
Owners Manual
Page 53
... owner's manual and on the safety decals. Always read and understand the load distribution warning labels on the rear rack) and mounted as low as possible. When operating over rough or hilly terrain, reduce speed and cargo weight to extend belt life. 50 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...
... owner's manual and on the safety decals. Always read and understand the load distribution warning labels on the rear rack) and mounted as low as possible. When operating over rough or hilly terrain, reduce speed and cargo weight to extend belt life. 50 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...
Owners Manual
Page 54
... front rack. When handling off-centered loads that extend over rough or hilly terrain, reduce speed and cargo to the hitch point designated for your vehicle. Carrying loads on a level grass surface. Always attach the tow load to maintain stable driving conditions. S DO NOT TRAVEL FASTER THAN THE RECOMMENDED SPEEDS. S HEAVY LOADS CAN CAUSE BRAKING AND CONTROL PROBLEMS. Use extreme caution when applying brakes with...
... front rack. When handling off-centered loads that extend over rough or hilly terrain, reduce speed and cargo to the hitch point designated for your vehicle. Carrying loads on a level grass surface. Always attach the tow load to maintain stable driving conditions. S DO NOT TRAVEL FASTER THAN THE RECOMMENDED SPEEDS. S HEAVY LOADS CAN CAUSE BRAKING AND CONTROL PROBLEMS. Use extreme caution when applying brakes with...
Owners Manual
Page 66
... left lower side of the engine, below the clutch box (700). Noise Emission Control System EMISSION CONTROL SYSTEMS Do not modify the engine, intake or exhaust components, as doing so may affect compliance with European directives 97/24/EC and 89/336/EEC. 63 EPA noise control requirements (40 CFR 205) and local noise level requirements. Your Polaris vehicle has a spark arrestor that the operator perform. All exhaust...
... left lower side of the engine, below the clutch box (700). Noise Emission Control System EMISSION CONTROL SYSTEMS Do not modify the engine, intake or exhaust components, as doing so may affect compliance with European directives 97/24/EC and 89/336/EEC. 63 EPA noise control requirements (40 CFR 205) and local noise level requirements. Your Polaris vehicle has a spark arrestor that the operator perform. All exhaust...
Owners Manual
Page 70
...with oil change " Oil tank vent hose (if equipped) J Valve clearance E E J Fuel system/filter " Radiator (if applicable) (if applicable) 100 H 100 H 100 H 100 H 12 M 12 M 12 M 12 M 1000 (1600) 1000 (1600) 1000 (1600) 1000 (1600) " Cooling hoses " Engine mounts Exhaust muffler/ pipe " Perform these services. 67 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 " Oil filter change...
...with oil change " Oil tank vent hose (if equipped) J Valve clearance E E J Fuel system/filter " Radiator (if applicable) (if applicable) 100 H 100 H 100 H 100 H 12 M 12 M 12 M 12 M 1000 (1600) 1000 (1600) 1000 (1600) 1000 (1600) " Cooling hoses " Engine mounts Exhaust muffler/ pipe " Perform these services. 67 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 " Oil filter change...
Owners Manual
Page 105
... waxed with any water that have entered the engine or exhaust system. Use a professional type washing mitten, cleaning the upper body first and the lower parts last. Do not allow the vehicle to run for your Polaris dealer. Polaris recommends washing the ATV by hand or with a chamois to prevent water spots. MAINTENANCE AND LUBRICATION Accessories Auxiliary power outlets provide 12V power for all...
... waxed with any water that have entered the engine or exhaust system. Use a professional type washing mitten, cleaning the upper body first and the lower parts last. Do not allow the vehicle to run for your Polaris dealer. Polaris recommends washing the ATV by hand or with a chamois to prevent water spots. MAINTENANCE AND LUBRICATION Accessories Auxiliary power outlets provide 12V power for all...
Owners Manual
Page 115
... full throttle. Drive Belt and Cover Problems Possible Cause Driving onto a pickup or tall trailer in high range Starting out going up belt Wrong or missing belt Improper break-in a new belt and/or clutch by operating below 30 mph for more when temperature is highly recommended for damage if repeated leaking occurs. With the transmission ATVs exposed to neutral. Clutch malfunction Poor engine performance Slippage from water Shift the transmission...
... full throttle. Drive Belt and Cover Problems Possible Cause Driving onto a pickup or tall trailer in high range Starting out going up belt Wrong or missing belt Improper break-in a new belt and/or clutch by operating below 30 mph for more when temperature is highly recommended for damage if repeated leaking occurs. With the transmission ATVs exposed to neutral. Clutch malfunction Poor engine performance Slippage from water Shift the transmission...
Owners Manual
Page 119
SPECIFICATIONS SPORTSMAN 450 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 450 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 121
SPECIFICATIONS SPORTSMAN 500 Gross Vehicle Weight Hitch To w ing 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 * Based on EU Directive 76/432/...
SPECIFICATIONS SPORTSMAN 500 Gross Vehicle Weight Hitch To w ing 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 * Based on EU Directive 76/432/...
Owners Manual
Page 123
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 * Based on EU Directive 76/432/EC 1240 lbs./563...
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 * Based on EU Directive 76/432/EC 1240 lbs./563...
Owners Manual
Page 127
... THE DEALER IS YOUR RESPONSIBILITY). POLARIS FURTHER DISCLAIMS ALL EXPRESS WARRANTIES NOT STATED IN THIS WARRANTY. Damage resulting from state to perform warranty service. WARRANTY ALL IMPLIED WARRANTIES (INCLUDING BUT NOT LIMITED TO THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE) ARE LIMITED IN DURATION TO THE ABOVE SIX MONTH WARRANTY PERIOD. Engine Oil 1. If any warranty issues. We recommend the use...
... THE DEALER IS YOUR RESPONSIBILITY). POLARIS FURTHER DISCLAIMS ALL EXPRESS WARRANTIES NOT STATED IN THIS WARRANTY. Damage resulting from state to perform warranty service. WARRANTY ALL IMPLIED WARRANTIES (INCLUDING BUT NOT LIMITED TO THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE) ARE LIMITED IN DURATION TO THE ABOVE SIX MONTH WARRANTY PERIOD. Engine Oil 1. If any warranty issues. We recommend the use...
Owners Manual
Page 134
... Oil Change (700) ...75 Oil Check ...70-71 Oil Pump Priming ...74 Oil, Engine ...70-75 Operator Safety ...11-30 T Tachometer ...42 Taillight ...92 Throttle Cable Freeplay ...109 Throttle Lever ...32 Tires ...86 Toe Alignment ...84 Transmission Oil (450/500) ...76 Transmission Oil (700) ...78 Transporting the ATV ...106 Trip Meter ...42 Troubleshooting ...112-115 Turning Around on a Hill ...58 P Parking Brake ...35 Parking on an Incline ...62 Periodic Maintenance Chart ...64-68 Polaris...
... Oil Change (700) ...75 Oil Check ...70-71 Oil Pump Priming ...74 Oil, Engine ...70-75 Operator Safety ...11-30 T Tachometer ...42 Taillight ...92 Throttle Cable Freeplay ...109 Throttle Lever ...32 Tires ...86 Toe Alignment ...84 Transmission Oil (450/500) ...76 Transmission Oil (700) ...78 Transporting the ATV ...106 Trip Meter ...42 Troubleshooting ...112-115 Turning Around on a Hill ...58 P Parking Brake ...35 Parking on an Incline ...62 Periodic Maintenance Chart ...64-68 Polaris...