2005 Polaris Sportsman 600 Problems and Repair Information
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Popular 2005 Polaris Sportsman 600 Manual Pages
Owners Manual - Page 6
... and is outlined in the Polaris Service Manual and should be sure to our world-wide family of your vehicle, be performed only by a Factory Certified Master Service Dealer (MSD) Technician. Many years of experience have gone into the engineering, design, and development of your service needs during, and after, the warranty period. We proudly produce an exciting...
Owners Manual - Page 12
..., carried as low as possible, and firmly secured to 80_ F. S Operation of this vehicle without the air filter element will increase your Owner's Manual. S Specific carburetor jetting and adjustments are required depending on rough or hilly terrain, reduce speed and cargo. TIRE PRESSURE IN PSI (KPa): FRONT 5 (34,5) REAR 5 (34,5) MAXIMUM WEIGHT CAPACITY (Gross...
Owners Manual - Page 16
...vehicle handles differently than other than a Polaris dealer, you purchased a used Polaris ATV from a party other vehicles, such as motorcycles and cars. Age Restrictions
This vehicle is an off-road vehicle. Read and understand your owner's manual... on your vehicle are responsible for anyone under 16 years of vehicle safety. A... Know Your Vehicle
As the operator of the vehicle, you fail ...
Owners Manual - Page 46
... is moved, this indicates the gear the transmission is in the fuel tank. This warning usually indicates that the ATV is enabled. 9 1 3. The segments of the fuel gauge show the level of the AWD system is being operated at idle and high electrical load (lights, cooling fan, accessories) is applied. A low battery warning may have...
Owners Manual - Page 63
...body weight uphill. 2. While holding the service brake, release the parking brake lock and slowly allow the vehicle to your right until the vehicle is on the left . 5. OPERATION
... brake and proceed slowly, controlling speed with the transmission still in forward and shut off the engine. 3. Lock the parking brake and remount the vehicle from the uphill side, keeping body weight uphill....
Owners Manual - Page 64
... water, it's critical to a dealer before starting the engine. The following areas need special attention: engine oil, transmission oil, front and rear gearcases, and all grease fittings. NOTE: Avoid operating the vehicle through water:
OPERATION
1. Proceed slowly, avoiding rocks and obstacles if possible. 4. Perform the services outlined in water that exceeds the recommended maximum depth...
Owners Manual - Page 69
...riding conditions and an average vehicle speed of important components are critical.
Vehicles subjected to severe use genuine Polaris parts available from your Polaris dealer. WARNING
Improperly performing the procedures marked with safe service and adjustment procedures, have a qualified dealer perform these procedures more frequently. NOTE: Service and adjustments are explained in...
Owners Manual - Page 70
.../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 change coolant every 2 years Check operation; clean if needed
J Steering " Front suspension " Rear suspension
Make adjustments j as needed See Pre...
Owners Manual - Page 71
... change " Oil tank vent hose
E (if equipped) E E
J Valve clearance 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.
68 lubricate; replace as needed Inspect coolant strength seasonally; E Emission...
Owners Manual - Page 91
... nut retention are installed properly. Always use original equipment size and type when replacing tires. Elevate the side of the vehicle by your ATV and in the owner's manual. Maintain proper tire pressure as described on the decal on your authorized Polaris dealer. All service must be performed by placing a suitable stand under the footrest frame. 4.
Owners Manual - Page 99
... below the footrests. 2. MAINTENANCE AND LUBRICATION
Vehicle Immersion
CAUTION
If your vehicle becomes immersed, major engine damage can result if the machine is evident. 3. Turn the fuel valve off. 4. Dry the spark plug and...Turn the fuel valve on page 99 for any water and dry it if water is present. Move the ATV to dry land or at the very least, to your dealer for service as soon ...
Owners Manual - Page 102
... PVT system is intended for service as soon as possible.
99 PVT Drying
There may occur at high speeds, creating large amounts of this product. Take the vehicle to your dealer as the owner...Remove the drain plug and allow the water to dry it in the owner's manual. Start the engine and shift the transmission into the PVT system. See your dealer for use on components. However, ...
Owners Manual - Page 107
... after washing, and allow the vehicle to run for a while to the wheel bearings, transmission seals, body panels, brakes and... warning labels. Cleaning and Storage
See page 113 for the part numbers of a high pressure type car wash system for your ATV can scratch the body finish. Polaris does not recommend the use of additional accessories...
Owners Manual - Page 117
... material in gas tank, fuel lines, or carburetor. WARNING: Excessive throttle may cause loss of control and vehicle overturn.
Use the throttle quickly and effectively for efficient engagement. Climbing over large objects from water Shift the transmission to about 1/8 throttle in neutral, advance the throttle to neutral. TROUBLESHOOTING
Drive Belt and Cover Problems
Possible Cause...
Owners Manual - Page 120
... See your Polaris dealer Set gap to specs or replace plugs Check all connections and tighten Recharge battery to flush any debris from the radiator fins. Plugged Radiator
117 TROUBLESHOOTING
Engine Stops or Loses Power
Possible Cause
Out of fuel Kinked or plugged fuel vent line Water present in screen
Solution
Remove and clean...
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... BKR5E / .035 in. (0.9 mm) Dry Sump Automatic PVT (Polaris Variable Transmission)
118
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... Transmission)
* Based on EU Directive 76/432/EC
120
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 ...
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 ...
Owners Manual - Page 131
...must present your original selling dealer; This warranty gives you specific legal rights, and you must take it to a Polaris dealer authorized to perform warranty service. When requesting warranty service you may use of the Warranty Registration form to state. Please work with controlling state law. WARRANTY
ALL IMPLIED WARRANTIES (INCLUDING BUT NOT LIMITED TO THE IMPLIED...
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