Owners Manual
Page 10
... if load extends over the side of this vehicle without pre-filter. See your risk of control resulting in dusty conditions. 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. S Operation of the rack. Safety Decals and Locations SAFETY WARNING IMPROPER TIRE PRESSURE OR OVERLOADING can cause engine damage. S Specific carburetor jetting...
... if load extends over the side of this vehicle without pre-filter. See your risk of control resulting in dusty conditions. 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. S Operation of the rack. Safety Decals and Locations SAFETY WARNING IMPROPER TIRE PRESSURE OR OVERLOADING can cause engine damage. S Specific carburetor jetting...
Owners Manual
Page 18
..., apply them lightly several times to allow friction to ) mowers, blades, tires, sprayers, or large racks, may increase the speed or power of bodily injury. S Always use of the vehicle. Allow a greater distance for your ATV, and always maintain proper tire pressure. Equipment Modifications We are concerned for the safety of tires specified for braking. NOTE: The addition of certain accessories, including (but...
..., apply them lightly several times to allow friction to ) mowers, blades, tires, sprayers, or large racks, may increase the speed or power of bodily injury. S Always use of the vehicle. Allow a greater distance for your ATV, and always maintain proper tire pressure. Equipment Modifications We are concerned for the safety of tires specified for braking. NOTE: The addition of certain accessories, including (but...
Owners Manual
Page 45
... transporting. CONTROLS Choke 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 procedure on the left side panel. Do not attempt to the engine starting a cold engine. Use either leaded or unleaded gasoline with a minimum pump octane number of operation, or annually. OFF ON Fuel Tank The fuel tank filler cap (2) is...
... transporting. CONTROLS Choke 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 procedure on the left side panel. Do not attempt to the engine starting a cold engine. Use either leaded or unleaded gasoline with a minimum pump octane number of operation, or annually. OFF ON Fuel Tank The fuel tank filler cap (2) is...
Owners Manual
Page 46
... model. H: High Gear L: Low Gear N: Neutral R: Reverse P: Park To shift into HIGH or PARK. To change gears, stop the vehicle, and with the engine speed above idle or while the vehicle is moving could cause transmission damage. When shifting out of the vehicle. Apply the auxiliary brake if shifting into HIGH or PARK, you must first apply the auxiliary brake to the desired gear. Belt Life To extend belt life, use low forward gear in PARK and lock...
... model. H: High Gear L: Low Gear N: Neutral R: Reverse P: Park To shift into HIGH or PARK. To change gears, stop the vehicle, and with the engine speed above idle or while the vehicle is moving could cause transmission damage. When shifting out of the vehicle. Apply the auxiliary brake if shifting into HIGH or PARK, you must first apply the auxiliary brake to the desired gear. Belt Life To extend belt life, use low forward gear in PARK and lock...
Owners Manual
Page 47
... light in the instrument cluster will be on . See page 36. If the rear wheels are spinning, release the throttle before getting into conditions where front wheel drive may cause severe drive shaft and gearcase damage. Always switch to the length of AWD in AWD, the front gearcase will automatically disengage. When the rear wheels regain traction, the front gearcase will automatically engage any time the rear wheels lose traction. Initially, the vehicle...
... light in the instrument cluster will be on . See page 36. If the rear wheels are spinning, release the throttle before getting into conditions where front wheel drive may cause severe drive shaft and gearcase damage. Always switch to the length of AWD in AWD, the front gearcase will automatically disengage. When the rear wheels regain traction, the front gearcase will automatically engage any time the rear wheels lose traction. Initially, the vehicle...
Owners Manual
Page 49
... gear the transmission is in the fuel tank. As the shift lever is moved, this warning appears or serious engine damage could result. 9. When the last segment clears, a low fuel warning is enabled. 9 1 3. Check Engine Warning Indicator - Fuel Gauge - Do not continue to your Polaris dealer for 2.5 seconds at a higher RPM or connecting a battery charger will light up . Driving at start-up for proper diagnosis. 1. FEATURES Instrument Cluster The rider information center...
... gear the transmission is in the fuel tank. As the shift lever is moved, this warning appears or serious engine damage could result. 9. When the last segment clears, a low fuel warning is enabled. 9 1 3. Check Engine Warning Indicator - Fuel Gauge - Do not continue to your Polaris dealer for 2.5 seconds at a higher RPM or connecting a battery charger will light up . Driving at start-up for proper diagnosis. 1. FEATURES Instrument Cluster The rider information center...
Owners Manual
Page 51
... machine out of the tires will remain lit. This information is activated. Hold the mode/reverse override button and turn the key switch off and wait 10 seconds. 2. Release the switch as soon as the gauge is flowing through the diagnostic screens. Set the park brake and shift the transmission to toggle through the AWD coil (only on models with switchable AWD). To enter the...
... machine out of the tires will remain lit. This information is activated. Hold the mode/reverse override button and turn the key switch off and wait 10 seconds. 2. Release the switch as soon as the gauge is flowing through the diagnostic screens. Set the park brake and shift the transmission to toggle through the AWD coil (only on models with switchable AWD). To enter the...
Owners Manual
Page 54
... miles. 51 Perform regular checks on fluid levels, controls and areas outlined on the dipstick. No single action on your new Polaris ATV is as important as the first ten hours of operation, or the time it takes to maintain the level between the safe and add marks. 3. Fill the fuel tank with vehicle operation and handling. 4. Vary the throttle positions. Perform...
... miles. 51 Perform regular checks on fluid levels, controls and areas outlined on the dipstick. No single action on your new Polaris ATV is as important as the first ten hours of operation, or the time it takes to maintain the level between the safe and add marks. 3. Fill the fuel tank with vehicle operation and handling. 4. Vary the throttle positions. Perform...
Owners Manual
Page 58
... designed to extend belt life. 55 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 section of load. When operating over rough or hilly terrain, reduce speed and cargo weight to maintain stable driving conditions. Always read and understand the load distribution warning labels on the rear rack) and mounted as...
... designed to extend belt life. 55 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 section of load. When operating over rough or hilly terrain, reduce speed and cargo weight to maintain stable driving conditions. Always read and understand the load distribution warning labels on the rear rack) and mounted as...
Owners Manual
Page 59
... LOADS CAN CAUSE BRAKING AND CONTROL PROBLEMS. Use extreme caution when applying brakes with loads that extend over rough or hilly terrain, reduce speed and cargo to overturn. Unsecured loads can alter vehicle handling and may require backing downhill. S USE EXTREME CAUTION when operating with a loaded vehicle. Vehicle should never exceed 10 mph (16 kph) while towing a load on the front rack.
... LOADS CAN CAUSE BRAKING AND CONTROL PROBLEMS. Use extreme caution when applying brakes with loads that extend over rough or hilly terrain, reduce speed and cargo to overturn. Unsecured loads can alter vehicle handling and may require backing downhill. S USE EXTREME CAUTION when operating with a loaded vehicle. Vehicle should never exceed 10 mph (16 kph) while towing a load on the front rack.
Owners Manual
Page 75
... 24 months 36 months 36 months Radiator Cooling system hoses J Clutches (drive and driven) Engine mounts J Brake fluid J Front wheel bear- adjust when parts are replaced As required Adjust as dirty or wet conditions L Emission Control System Service (California) J Dealer service item 72 replace as needed Check for leaks at tank cap, lines, fuel valve, filter, pump and carburetor; adjust and lubricate if needed Inspect bearings; MAINTENANCE AND LUBRICATION Periodic Maintenance Schedule WARNING Improperly performing the procedures marked with a J could...
... 24 months 36 months 36 months Radiator Cooling system hoses J Clutches (drive and driven) Engine mounts J Brake fluid J Front wheel bear- adjust when parts are replaced As required Adjust as dirty or wet conditions L Emission Control System Service (California) J Dealer service item 72 replace as needed Check for leaks at tank cap, lines, fuel valve, filter, pump and carburetor; adjust and lubricate if needed Inspect bearings; MAINTENANCE AND LUBRICATION Periodic Maintenance Schedule WARNING Improperly performing the procedures marked with a J could...
Owners Manual
Page 110
... replacement. Accessory outlets are damaged, contact your a Polaris dealer for your ATV is used, exercise extreme care to avoid water damage to the wheel bearings, transmission seals, body panels, brakes and warning labels. CAUTION 107 Cleaning and Storage See page 115 for all zerk fittings immediately after washing, and allow the vehicle to run for operating accessories such as hand held spot lights. If a high pressure...
... replacement. Accessory outlets are damaged, contact your a Polaris dealer for your ATV is used, exercise extreme care to avoid water damage to the wheel bearings, transmission seals, body panels, brakes and warning labels. CAUTION 107 Cleaning and Storage See page 115 for all zerk fittings immediately after washing, and allow the vehicle to run for operating accessories such as hand held spot lights. If a high pressure...
Owners Manual
Page 119
... engage clutch. Poor engine performance. Starting out going up of low range is highly recommended for efficient engagement. Insufficient warm-up a steep incline. Shift the transmission to low range, and carefully use fast, aggressive throttle application to low range during loading of control and vehicle overturn. low ground speed (at least 5 minutes. TROUBLESHOOTING Drive Belt and Cover Problems Possible Cause Driving the ATV onto a pickup or tall trailer...
... engage clutch. Poor engine performance. Starting out going up of low range is highly recommended for efficient engagement. Insufficient warm-up a steep incline. Shift the transmission to low range, and carefully use fast, aggressive throttle application to low range during loading of control and vehicle overturn. low ground speed (at least 5 minutes. TROUBLESHOOTING Drive Belt and Cover Problems Possible Cause Driving the ATV onto a pickup or tall trailer...
Owners Manual
Page 123
SPECIFICATIONS SPORTSMAN 400 Gross Vehicle Weight 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 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 (Rear rack weight and tongue weight not...
SPECIFICATIONS SPORTSMAN 400 Gross Vehicle Weight 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 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 (Rear rack weight and tongue weight not...
Owners Manual
Page 125
SPECIFICATIONS SPORTSMAN 500 Gross Vehicle Weight Hitch Towing Rating Unbraked Trailer 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 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 lbs./810 kg 120 ...
SPECIFICATIONS SPORTSMAN 500 Gross Vehicle Weight Hitch Towing Rating Unbraked Trailer 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 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 lbs./810 kg 120 ...
Owners Manual
Page 127
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 129
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
..., you have received authorization for export. Dealers may also be authorized to determine this vehicle's warranty or service bulletin coverage if you should consult an authorized dealer to perform the warranty repair. If you move to another country, be required to contact Polaris Customer Assistance and the customs department of the selling dealer's authorized location. Upon residence...
..., you have received authorization for export. Dealers may also be authorized to determine this vehicle's warranty or service bulletin coverage if you should consult an authorized dealer to perform the warranty repair. If you move to another country, be required to contact Polaris Customer Assistance and the customs department of the selling dealer's authorized location. Upon residence...
Owners Manual
Page 136
... ...104 Battery Removal ...104 Battery Storage ...105 Belt Life ...43 Brake Fluid ...39, 41 Brake Lever ...38 Brake, Auxiliary ...41 Brake, Parking ...40 Brakes ...87-88 Break-In Period ...51 Breather Filter ...93 F FEATURES ...44-49 Filter Systems ...93 Front Gearcase Oil ...82 Front Wheel Hub Tightening ...92 Fuel Filter ...42 Fuel Safety ...50 Fuel Tank ...42 Fuel Valve ...42 G Gear Selector ...43 H Handlebars ...112 Hauling Cargo ...55-56 Headlight Housing Replacement ...96 Headlight Lamp Replacement ...94 Headlamp (Lower...
... ...104 Battery Removal ...104 Battery Storage ...105 Belt Life ...43 Brake Fluid ...39, 41 Brake Lever ...38 Brake, Auxiliary ...41 Brake, Parking ...40 Brakes ...87-88 Break-In Period ...51 Breather Filter ...93 F FEATURES ...44-49 Filter Systems ...93 Front Gearcase Oil ...82 Front Wheel Hub Tightening ...92 Fuel Filter ...42 Fuel Safety ...50 Fuel Tank ...42 Fuel Valve ...42 G Gear Selector ...43 H Handlebars ...112 Hauling Cargo ...55-56 Headlight Housing Replacement ...96 Headlight Lamp Replacement ...94 Headlamp (Lower...
Owners Manual
Page 137
... Spark Arrestor ...100 Spark Plug Removal/Replacement ...98 Spark Plugs ...98 SPECIFICATIONS ...120-127 Starting a Cold Engine ...53 Starting a Warm Engine ...54 Starting the Engine ...53-54 Steering Assembly ...89 Stop Switch ...36 Storage ...107-110 Storage Tips ...108-110 Switches ...36 N Noise Emission Control System ...68 O Odometer ...47 Oil Change ...78 Oil Change (400/500) ...78-79 Oil Change (600/700) ...80 Oil Check ...77 Oil Filter Change ...78 Oil, Front Gearcase ...82 Oil Pump Priming ...79 Oil, Rear Gearcase (600/700) ...84 Oil, Transmission (400/500) ...81 Oil, Transmission...
... Spark Arrestor ...100 Spark Plug Removal/Replacement ...98 Spark Plugs ...98 SPECIFICATIONS ...120-127 Starting a Cold Engine ...53 Starting a Warm Engine ...54 Starting the Engine ...53-54 Steering Assembly ...89 Stop Switch ...36 Storage ...107-110 Storage Tips ...108-110 Switches ...36 N Noise Emission Control System ...68 O Odometer ...47 Oil Change ...78 Oil Change (400/500) ...78-79 Oil Change (600/700) ...80 Oil Check ...77 Oil Filter Change ...78 Oil, Front Gearcase ...82 Oil Pump Priming ...79 Oil, Rear Gearcase (600/700) ...84 Oil, Transmission (400/500) ...81 Oil, Transmission...