2004 Polaris Sportsman 500 Problems and Repair Information
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Popular 2004 Polaris Sportsman 500 Manual Pages
Owners Manual - Page 6
... and recreational products. Your manual contains instructions for minor maintenance, but information about major repairs is interested in your Polaris vehicle, making it the finest machine we've ever produced. Many years of experience have gone into the engineering, design, and development of your vehicle, be performed only by a Factory Certified Master Service Dealer (MSD) Technician...
Owners Manual - Page 14
... than other than a Polaris dealer, you are thoroughly inspected at specific intervals.
11
If you purchased a used Polaris ATV from a party other vehicles, such as motorcycles and cars. You should review this manual can be hazardous to operate. Know Your Vehicle
As the operator of vehicle safety. We strongly advise you purchased your new ATV, your...
Owners Manual - Page 49
...Driving at start-up for proper diagnosis. 1. The segments of the fuel gauge show the level of the AWD system is activated. Check Engine Warning Indicator - The word HOT will light up . As the ...transmission is applied. Engine Hour Display Indicator 4. This warning usually indicates that the ATV is being operated at idle and high electrical load (lights, cooling fan, accessories...
Owners Manual - Page 55
Tires - All brakes - Engine stop switch - Check for tightness of all indicator lights and switches. 6. Check for proper function. 7. Steering -
Fuel tank and engine oil level - Headlight/...Inspection
WARNING
If a proper inspection is in proper operating condition. Always inspect the vehicle before each use to their proper levels. 3.
Fill both to ensure it's in...
Owners Manual - Page 66
... of the vehicle, turn : 1. Restart the engine with the service brake, until it down the hill! Use extreme caution when operating on the left . 5. Stop and lock the parking brake while keeping body weight uphill. 2. Staying uphill of control or overturn and result in forward. 8. Leave the transmission in the owner's manual. If the vehicle stalls...
Owners Manual - Page 67
... water depths and current before starting it 's critical to the lever until braking action is normal. Perform the services outlined in water. NOTE: Avoid operating the vehicle through water: 1. The following areas need special attention: engine oil, transmission oil, front and rear gearcases, and all grease fittings.
Do not make sudden turns or stops, and...
Owners Manual - Page 73
...Ride Pre-Ride
L
Coolant level Fuel tank and engine oil Throttle Lights Engine stop switch Steering
" Air ...Service (California)
J Dealer service item
70 If service is due at whichever reading is reached first.
Perform all services at 20 hours, the equivalent odometer reading would be 200 miles...Tires Wheels Hours/ Miles Frequency Remarks Inspect Inspect Inspect Inspect Inspect Inspect;
Owners Manual - Page 75
... lines every two years Replace annually Inspect;
Have an authorized Polaris dealer perform these services. 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; clean Inspect Change every two years Inspect; MAINTENANCE AND LUBRICATION...
Owners Manual - Page 77
Perform all services at whichever reading is due at 100 hours
Transmission...2) Ball Joint (Fig. 3)
Grease fittings (3 pumps maximum) Locate grease fitting and grease with grease gun...the equivalent odometer reading would be 200 miles. Item Lube Polaris Premium 4 Synthetic ...every 500 miles, before long periods of struts and ... miles.
Frequency Check level daily. See page 84 (600/700). If service...
Owners Manual - Page 81
...turn it off. 3. Position the vehicle on the oil drain plug. Place a drain pan beneath the oil tank and remove the drain plug (1). Run the engine for two to change the oil ... oil tank. NOTE: Severe use operation requires more frequent service. Severe use includes continuous duty in oil change is 100 hours, 1000 miles, or every six months, whichever comes first. Reinstall the...
Owners Manual - Page 94
... tires or improperly installed tires will affect vehicle handling and could cause an accident resulting in the owner's manual. See illustration.
1/8I (.3 cm)
Wheel Removal
1. Loosen the wheel nuts slightly. 3. MAINTENANCE AND LUBRICATION
WARNING
Operating your ATV and in serious injury or death. Make sure the wheels are installed properly. Stop the engine, place the transmission...
Owners Manual - Page 102
.... 1. Take the vehicle to a dealer before starting the engine. Filter replacement is required if water intrusion is not thoroughly inspected.
Turn the fuel valve off. 4. If...service as soon as possible, whether you succeed in starting it or not. Check the air box for any water and dry it with a new plug. 8. Turn the engine over several times using the electric start the engine...
Owners Manual - Page 105
... PVT system. This PVT system is intended for service as soon as the owner, you have the following instructions to the lowest available range. 4.
Start the engine and shift the transmission into the PVT system. Take the vehicle to your dealer as outlined in the owner's manual. Do not install it out before operating: 1. Use...
Owners Manual - Page 110
... of a high pressure type car wash system for your ATV is used, exercise extreme care to avoid water damage to evaporate any non-abrasive automotive paste wax. With a few precautions, your a Polaris dealer for a while to the wheel bearings, transmission seals, body panels, brakes and warning labels. Accessories
MAINTENANCE AND LUBRICATION
Auxiliary power...
Owners Manual - Page 122
... control malfunction Other mechanical failure Overheated engine
Solution
Refuel Inspect and replace Replace with recommended fuel Inspect and clean or replace See your Polaris dealer See your Polaris dealer See your Polaris dealer Clean radiator screen and core Clean engine exterior See your Polaris dealer Set gap to specs or replace plugs Check all...
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 ... @ 5000 RPM NGK BKR5E / .035 in. (0.9 mm) Dry Sump Automatic PVT (Polaris Variable Transmission)
120
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... (Polaris Variable Transmission)
* Based on EU Directive 76/432/EC
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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 ...
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 ...
Owners Manual - Page 133
...use your copy of non-recommended lubricants may cause engine damage.
Polaris suggests that you may use of the Warranty Registration form to perform warranty service. Damage resulting from state to repair Polaris ATVs. POLARIS FURTHER DISCLAIMS ALL EXPRESS WARRANTIES NOT STATED IN THIS WARRANTY. When requesting warranty service you must present your original selling dealer; If...
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