Polaris Sportsman S User Manual

8SAFETYSafety Decals and LocationsMoving parts haz ar d under belt -c lut c h guard. Toprev ent ser ious injury, do not oper ate vehic le withguard re

98MAINTENANCE AND LUBRICATIONLightsHigh Beam Adjus tmentThe headlight beam can be adjusted to any position desired by turningthe adjusting knob on the

99MAINTENANCE AND LUBRICATIONLightsHeadlight Housing Replacement1. Remove the two screws on the lower front corners of the headlightpod.2. Using a sma

100MAINTENANCE AND LUBRICATIONLightsLower Headlamp Removal / Installatio n1. Turn the back of the headlight harness (1) in aclockwise direction.2. Pul

101MAINTENANCE AND LUBRICATIONSpark PlugsS Use BKR5E spark plugs for the Sportsman 400 and 500.S Use RC7YC spark plugs for the Sportsman 600 and 700.S

102MAINTENANCE AND LUBRICATIONVehicle ImmersionIf it’s impossible to take your ATV to a dealer before starting it, followthe steps outlined below.1. M

103MAINTENANCE AND LUBRICATIONSpark ArrestorUse the following procedure to periodically purge accumulated carbonfrom t he exhaust pipe/muffler.1. Remo

104MAINTENANCE AND LUBRICATIONPVT SystemThe basic operation of the Polaris PVT system is dependent on enginespeed and vehicle torque requirements. As

105MAINTENANCE AND LUBRICATIONPVT SystemPVT DryingThere may be some instances when water is accidently ingested intothe PVT system. Use the following

106MAINTENANCE AND LUBRICATIONBatteryYour ATV m ay have either a sealed battery, which requires littlemaintenance, or a conventional battery. Keep the

107MAINTENANCE AND LUBRICATIONBatteryBattery Removal1. Disconnect the hold-down strap holding the battery in position, andremove battery cover.2. On c

9SAFETYSafety Decals and LocationsALL WHEELDRIVESWITCHDo not push switch toengage AW D if the rearwheels are spinning.This may cause severedrive shaft

108MAINTENANCE AND LUBRICATIONBatteryBattery StorageWhen the vehicle is placed in storage for three months or more, thebattery should be removed, stor

109MAINTENANCE AND LUBRICATIONBatteryBattery Charging (Sealed Battery)For a refresh charge, follow all instructions carefully.1. Check the battery vol

110MAINTENANCE AND LUBRICATIONAccessoriesAuxiliary power outlets provide 12V power for operating accessoriessuch as hand held spot lights. Accessory o

111MAINTENANCE AND LUBRICATIONCleaning and StorageStorage TipsClean the ExteriorMake necessary repairs and then clean the ATV thoroughly with mildsoap

112MAINTENANCE AND LUBRICATIONCleaning and StorageStorage TipsFog the Engine1. Re move the spark plug and add 2-3 tablespoons of Pr emium 4Synthetic 0

113MAINTENANCE AND LUBRICATIONCleaning and StorageStorage TipsBattery Maintenance (Conventional)Remove the battery and add distilled water to the prop

114ADJUSTMENTSCamb er and CasterThe camber and caster are non-adjustable.Rear SpringThe rear shock absorber spring isadjusted by rotating the adjuster

115ADJUSTMENTSCarburetor/Idle RPMIf the engine idle speed is not satisfactory, andall other conditions are favorable, the carburetorcan be adjusted.1.

116ADJUSTMENTSThrottle Cable FreeplayThrottle cable freeplay is adjusted at the handlebar.1. Slide the boots (1) off the inline cable adjuster sleeve

117TROUBLESHOOTINGDrive Belt an d Cover ProblemsPossible Cause SolutionDriving the ATV onto apickup or tall trailer inhigh range.Shift transmission to

10SAFETYSafe Riding GearAlways wear clothing suited to the type of riding. ATV riding requiresspecial protective clothing for comfort and to reduce th

118TROUBLESHOOTINGContact your Polaris dealer for service if you’re unable to identifysolutions using the following charts.Engine Doesn’t Tu rn OverPo

119TROUBLESHOOTINGEngine BackfiresPossible Cause SolutionWeak spark from spark plugs Inspect, clean and/or replace spark plugsIncorrect spark plug gap

120TROUBLESHOOTINGEngine Stops or Loses PowerPossible Cause SolutionOut of fuel Turn fuel valve to reserve, refuelKinked or plugged fuel vent line Ins

121POLARIS PRODUCTSPart No. DescriptionEngine Lubricant2870791 Fogging Oil (12 oz. Aerosol)2871281 Engine Oil (qt.) Premium 4 Synthetic 0W-40 (4-Cycle

122SPECIFICATIONSSPORTSMAN 400Gross Vehicle Weight 1200 lbs./544 kgTowing Capacity 1225 lbs./556 kgHitch Tongue Capacity 120 lbs./54 kg (Rear rack wei

123SPECIFICATIONSSPORTSMAN 400Shift Type Side Lever (High, Low, Neutral, Reverse)Gear Reduction - Low 8.27/1Gear Reduction - Reverse 5.17/1Gear Reduct

124SPECIFICATIONSSPORTSMAN 500Gross Vehicle Weight 1200 lbs./544 kgHitch Towing Rating 1225 lbs./556 kgUnbraked Trailer

125SPECIFICATIONSSPORTSMAN 500Driving System Type EBSShift Type Side Lever (High, Low, Neutral, Reverse)Gear Reduction - Low 8.27/1Gear Reduction - Re

126SPECIFICATIONSSPORTSMAN 600Gross Vehicle Weight 1240 lbs./563 kgFuel Capacity 4.75 gal./18 lTowing Capacity 1500 lbs./681 kgHitch Tongue Capacity 1

127SPECIFICATIONSSPORTSMAN 600Shift Type Side Lever(High, Low , Neutral, Reverse, Park)Gear Reduction - Low 7.5/1Gear Reduction - Reverse 5.11/1Gear R

11SAFETYOperator SafetyAge RestrictionsThis vehicle is an ADULT VEHICLE ONLY. Operation is prohibite dfor anyone under 16 years of age.Know Your Vehic

128SPECIFICATIONSSPORTSMAN 700Gross Vehicle Weight 1240 lbs./563 kgFuel Capacity 4.75 gal./18 lTowing Rating 1500 lbs./681 kgUnbraked Trailer Towing C

129SPECIFICATIONSSPORTSMAN 700Shift Type Side Lever(High, Low , Neutral, Reverse, Park)Gear Reduction - Low 7.5/1Gear Reduction - Reverse 5.11/1Gear R

130WARRANTYLIMITED WARRANTYPolaris Sales Inc., 2100 Highway 55, Medina, MN 55340, gives a SIXMONTH LIMITED WARRANTY on all components of the Polaris A

131WARRANTYWARRANTY COVERAGE AND EXCLUSIONS:LIMITATIONS OF WARRANTIES AND REMEDIESThe Polaris limited warranty excludes any failures that are not caus

132WARRANTYALL IMPLIED WARRANTIES (INCLUDING BUT NOT LIMITEDTO THE IMPLIED WARRANTIES OF MERCHANTABILITY ANDFITNESS FOR A PARTICULAR PURPOSE) ARE LIMI

133WARRANTYExported VehiclesEXCEPT WHERE SPECIFICALLY REQUIRED BY LAW, THEREIS NO WARRANTY OR SERVICE BULLETIN COVERAGE ONTHIS VEHICLE IF IT IS SOLD O

134WARRANTYExported VehiclesHow to Get ServiceIf Purchased From A Private Party:If you purchase a Polaris product from a private citizen outside of th

135INDEXAAccessories 110...ADJUSTMENTS 114-116...Age Restrictions 11...Air Filter Service 96...All

136INDEXMMain Switch 36...MAINTENANCEAND LUBRICATION 69-113...Maintenance Record 74...Making Turns 58...M

Part No. 9918540 Rev 04PRINTED IN THE USAWARNINGImproper vehicle use can result in SEVERE INJURY or DEATH.READ OWNER'S MANUAL.FOLLOW ALL INSTRUC

12SAFETYOperator SafetyThe following two pages identify signal words and s ymbols that appearin this manual. Your safety is involved when these words

13SAFETYOperator SafetyS Read this manual and all labels carefully, and follow the operatingprocedures described.S Never operate an ATV without proper

14SAFETYOperator SafetyS Always have the ATV inspected by an authorized Polaris dealer ifit’s been involved in an accident.S Never operate on hills to

15SAFETYOperator SafetyS Wet brakes may have reduced stopping ability. Test the brakes afterleaving water. If necessary, apply them lightly several ti

16SAFETYOperator SafetyPOTENTIAL HAZARDOperating this ATV without proper instruction.WHAT CANHAPPENThe risk of an accident is greatly increased if the

17SAFETYOperator SafetyPOTENTIAL HAZARDCarrying a passenger on an ATV.WHAT CANHAPPENCarrying a passenger greatly reduces the operator’s ability tobala

WARNINGThe engine exhaust from thisproduct contains chemicals knownto cause cancer, birth defects orother reproductive harm.A card containing importan

18SAFETYOperator SafetyPOTENTIAL HAZARDOperating an ATV on paved surfaces, including sidewalks,paths, parking lots, and driveways.WHAT CANHAPPENATV ti

19SAFETYOperator SafetyPOTENTIAL HAZARDOperating this ATV on public streets, roads or highways.WHAT CANHAPPENThe ATV could collide with another vehicl

20SAFETYOperator SafetyPOTENTIAL HAZARDOperating this ATV without wearing an approved helmet, eyeprotection and protective clothing.WHAT CANHAPPENOper

21SAFETYOperator SafetyPOTENTIAL HAZARDOperating the ATV after consuming alcohol or drugs.WHAT CANHAPPENConsumption of alcohol and/or drugs could seri

22SAFETYOperator SafetyPOTENTIAL HAZARDAttempting wheelies, jumps and other stunts.WHAT CANHAPPENAttempting stunts increases the chance of an accident

23SAFETYOperator SafetyPOTENTIAL HAZARDFailure to inspect the ATV before operating.Failure to properly maintain the ATV.WHAT CANHAPPENPoor maintenance

24SAFETYOperator SafetyPOTENTIAL HAZARDFailure to use extra caution when operating the ATV on unfamiliarterrain.WHAT CANHAPPENUnfamiliar terrain may c

25SAFETYOperator SafetyPOTENTIAL HAZARDFailure to use extra caution when operating on excessivelyrough, slippery or loose terrain.WHAT CANHAPPENOperat

26SAFETYOperator SafetyPOTENTIAL HAZARDT urning improperly.WHAT CANHAPPENImproper turns could cause loss of control and lead to a collisionor overturn

27SAFETYOperator SafetyPOTENTIAL HAZARDClimbing hills improperly.WHAT CANHAPPENImproper hill climbing could cause loss of control or overturn.HOW TO A

1We’ve created a web site just for YOU!S Technical tipsS New product introductionsS Event schedulesS Parts and Service Manual informationS Exciting de

28SAFETYOperator SafetyPOTENTIAL HAZARDT raveling downhill improperly.WHAT CANHAPPENImproperly descending a hill could cause loss of control orovertur

29SAFETYOperator SafetyPOTENTIAL HAZARDImproperly crossing hills and turning on hills.WHAT CANHAPPENImproperly crossing or turning as hills could caus

30SAFETYOperator SafetyPOTENTIAL HAZARDStalling, rolling backwards orimproperly dismounting whileclimbing a hill.WHAT CANHAPPENThe vehicle could overt

31SAFETYOperator SafetyPOTENTIAL HAZARDImproperly operating over obstacles.WHAT CANHAPPENOperating over obstacles could cause loss of control or overt

32SAFETYOperator SafetyPOTENTIAL HAZARDOperating the ATV through deep or fast-flowing water.WHAT CANHAPPENT ires may float, causing loss of traction a

33SAFETYOperator SafetyPOTENTIAL HAZARDOperating this ATV with improper tires, or with improper or uneventire pressure.WHAT CANHAPPENUse of improper t

34SAFETYOperator SafetyPOTENTIAL HAZARDOverloading the ATV or carrying/towing cargo improperly.WHAT CANHAPPENOverloading and towing can cause changes

35SAFETYOperator SafetyOperating a damaged ATV can result in an accident with seriousinjury or death. After any overturn or accident, have a qualified

36CONTROLSEngine Electrical SwitchesMode/Reverse Override Switch (1) - This vehicle is equipped with areverse speed limiter system. To gain additional

37CONTROLSThrottle LeverEngine speed and vehiclemovement are controlled bypressing the throttle lever (1).The t hrottle lever is springloaded. Engine

2All information in this manual is based on the latest product data and specificationsavailable at the time of printing. Polaris Industries Inc. reser

38CONTROLSLight SwitchesThe light switch is l ocated on the left handlebar. It’s used to turn thelights on and off and to switch the lights from HI to

39CONTROLSMaster CylinderThe brake fluid in the mastercylinder (1), which is located on theleft handlebar, should be checkedbefore each ride. The flui

40CONTROLSParking BrakeSetting th e Parking Brake1. Place the transmission in firstgear (or in PARK if equipped).2. Squeeze and release the brakelever

41CONTROLSAuxiliary BrakeYour P olaris ATV has anauxiliary brake (1) for addedsafety. It’s located on theinside of the right floor boardand is operate

42CONTROLSChokeThe choke assists in starting a cold engine. Refer to the engine startingprocedure on page 53 for correct choke and throttle settings d

43CONTROLSAutomatic Transmission Gear SelectorThe transmission gear selector (1) is located on the right side of thevehicle. Shift patterns vary, depe

44FEATURESAll Wheel Drive (AWD) SystemPolaris 4-wheel drive ATVs areequipped with a unique,Polaris-exclusive, AWD system,which is activated by a switc

45FEATURESInstrument ClusterYour ATV i s equipped with an instrument cluster that senses vehiclespeed from the right front wheel. The instrument clust

46FEATURESInstrument ClusterRider Information CenterThe rider information center is located in the instrument cluster. Allsegments will light up for 2

47FEATURESInstrument ClusterRider Information CenterThe rider information center has 4 standard modes:Mode 1 - OdometerMode 2 - TripmeterMode 3 - Tota

3WELCOMEThank you for purchasing a Polaris vehicle, and welcome to ourworld-wide family of Polaris owners. We proudly produce an excitingline of utili

48FEATURESInstrument ClusterRider Information CenterDiagnostic ModeThe diagnostic mode is for informational purposes only. Please returnyour ATV to yo

49FEATURESInstrument ClusterRider Information CenterDiagnostic ModeScreen 5: Programmable service intervalThe purpose of the programmable service inte

50OPERATIONFuel SafetyGasoline is highly flammable and explosive under certainconditions.S Always exercise extreme caution whenever handling gasoline.

51OPERATIONBreak-In PeriodThe break-in period for your new Polaris ATV is defined as the first tenhours of operation, or the time it takes t o use the

52OPERATIONPre-Ride InspectionUse the following checklist to verify that your vehicle is in properworking condition before each use.Item/Inspection Pr

53OPERATIONStarting the EngineStarting a Cold Engine1. Place the transmission in neutral(or PARK if equipped) and lockthe parking brake.2. Turn the fu

54OPERATIONStarting the EngineStarting a Warm EngineWarm engines do not normally require the use of the choke. Using thechoke can cause the spark plug

55OPERATIONHauling CargoYour ATV has been designed to carry or tow a certain amount of load.Always read and understand the load distribution warning l

56OPERATIONHauling CargoHauling cargo improperly can alter vehicle handling and maycause loss of control or brake instability and result in serious in

57OPERATIONDriving SafelyDriving Procedures1. Sit upright with both feet on the footrests and both hands on thehandlebars.2. Start the engine and allo

4VEHICLE IDENTIFICATION NUMBERSThe frame vehicle identification number (VIN)(1) and engine serialnumber (2) are important for model identification whe

58OPERATIONDriving SafelyMaking Tu rnsYour ATV is equipped with a solid rear axle, which drives both rearwheels equally at all times. This means that

59OPERATIONDriving SafelyDriving on Slippery SurfacesWhenever riding on slippery surfaces such as wet trails or loose gravel,or during freezing weathe

60OPERATIONDriving SafelyTraveling UphillWhenever traveling uphill, follow these precautions:1. Always travel straight uphill.2. Avoid steep hills (25

61OPERATIONDriving SafelySidehillingSidehilling can be a dangerous type of driving and should be avoided ifat all possible. If you do enter i nto a si

62OPERATIONDriving SafelyTraveling DownhillWhenever descending a hill, follow these precautions:1. Proceed directly downhill.2. Transfer your weight t

63OPERATIONDriving SafelyTurning Around on a HillIf the vehicle stalls while climbing a hill, never back it down the hill!One maneuver t hat can be us

64OPERATIONDriving SafelyDriving Through WaterYour ATV can operate through waterwith a maximum recommendeddepth equal to the bottom ofthe footrests (1

65OPERATIONDriving SafelyDriving Over Ob staclesBe alert! Look ahead and learn to read the terrain you’re traveling on.Be constantly alert for hazards

66OPERATIONDriving SafelyDriving in ReverseFollow these precautions when operating in reverse:1. Always avoid backing downhill.2. Back slowly.3. When

67OPERATIONDriving SafelyParkingonanInclineAvoid parking on an incline if possible. If it’s unavoidable, followthese precautions:1. Turn the engine of

5TABLE OF CONTENTSWELCOME 3...VEHICLE IDENTIFICATION NUMBERS 4...TABLE OF CONTENTS 5...

68EMISSION CONTROL SYSTEMSNoise Emission Control SystemTAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED!U.S. Federal law prohibits the following acts or

69MAINTENANCE AND LUBRICATIONPeriodic Maintenance ScheduleCareful periodic maintenance will help keep your vehicle in the safest,most reliable conditi

70MAINTENANCE AND LUBRICATIONPeriodic Maintenance ScheduleHours of operation are based on a 10 mph average. If service is due at20 hours, the equivale

71MAINTENANCE AND LUBRICATIONPeriodic Maintenance ScheduleItem Hours/MilesFrequency Remarks" Air box sedimenttubePre-Ride Pre-Ride Drain deposits

72MAINTENANCE AND LUBRICATIONPeriodic Maintenance ScheduleItem Hours/MilesFrequency RemarksCarburetor floatbowl50 hrs. 6 months Drain bowl periodicall

73MAINTENANCE AND LUBRICATIONPeriodic Maintenance ScheduleItem Hours/MilesFrequency Remarks" Rear axle 50 hrs. 6 months Inspect bearings; lubeJLI

74MAINTENANCE AND LUBRICATIONPeriodic Maintenance RecordUse the following chart to record periodic maintenance.MaintenanceIntervalPerformedServicingDa

75-NOTES-

76MAINTENANCE AND LUBRICATIONLubrication GuideNOTE: Hours in the frequency column are based on 10 mph average.If service is due at 20 hours, the equiv

77MAINTENANCE AND LUBRICATIONLubrication Guide(Fig. 1)(Fig. 4)(Fig. 2)(Fig. 3)(Fig. 5)(Fig. 1)(Fig. 2)(Fig. 6)

6SAFETYSafety Decals and LocationsWarning decals have been placed on the ATV for your protection.Read and follow the instructions on each decal carefu

78MAINTENANCE AND LUBRICATIONPremium 4 Synthetic LubricantPolaris Premium 4 All Season synthetic engine oil has been speciallyformulated for use in Po

79MAINTENANCE AND LUBRICATIONOil CheckThe oil dipstick and fill tube (1) are located on the left side of thevehicle.1. Position the ATV on a level sur

80MAINTENANCE AND LUBRICATIONOil and Filter ChangeThe recommended oil change interval is 100 hours, 1000 miles, orevery six months, whichever comes fi

81MAINTENANCE AND LUBRICATIONOil Change (400/500)7. Place shop towels beneath the oil filter. Using an oil filter wrench,turn the filter (1) countercl

82MAINTENANCE AND LUBRICATIONOil Change (600/700)1. Place the vehicle on a level surface.2. Run the engine for two to three minutes until warm. Stop t

83MAINTENANCE AND LUBRICATIONTransmission Oil (400/500)The transmission oil level should be checked every six months or 1000miles (1600 km), whichever

84MAINTENANCE AND LUBRICATIONFront Gearcase Oil (400/500)The front gearcase lubricant level should be checked every s ix monthsor 1000 miles (1600 km)

85MAINTENANCE AND LUBRICATIONTransmission Oil (600/700)The transmission oil level should be checked every six months or 1000miles (1600 km), whichever

86MAINTENANCE AND LUBRICATIONFront Gearcase Oil (600/700)The front gearcase lubricant level should be checked every s ix monthsor 1000 miles (1600 km)

87MAINTENANCE AND LUBRICATIONRear Gearcase Oil (600/700)The rear gearcase lubricant level should be checked every six monthsor 1000 miles (1600 km), w

7SAFETYSafety Decals and LocationsIMPROPER TIRE PRESSURE OR OVERLOADING can c ause loss ofcontrol resulting in SEVERE INJURY OR DEATH.TIRE PRESSURE IN

88MAINTENANCE AND LUBRICATIONEngine Cooling SystemCoolant LevelThe recovery bottle (1) is located on theleft side of the machine. To access therecover

89MAINTENANCE AND LUBRICATIONEngine Cooling SystemRadiator Coolant LevelNOTE: This procedure i s requiredonly if the cooling system has beendrained fo

90MAINTENANCE AND LUBRICATIONFront BrakeThe front brakes are hydraulic disc brakes. They’re activated bymoving the brake lever toward the handlebar. T

91MAINTENANCE AND LUBRICATIONRear BrakeThe rear brake is a hydraulic disc brake andis activated by the same lever that activatesthe front brake system

92MAINTENANCE AND LUBRICATIONToe AlignmentUse the following procedure to check the t oe alignment of the vehicle.The recommended toe alignment is 1/8″

93MAINTENANCE AND LUBRICATIONSide Panel RemovalNOTE: Side panel removal m ay be difficult until the locking tabs andreceivers have been snapped and un

94MAINTENANCE AND LUBRICATIONT ire Tread DepthAlways replace tires when treaddepth is worn to 1/8″ (.3 cm) or less.See illustration.Wheel Removal1. St

95MAINTENANCE AND LUBRICATIONWheel Installation1. Place the transmission in gear(or in PARK if equipped)and lock t he parking brake.2. Place the wheel

96MAINTENANCE AND LUBRICATIONFilter SystemsAir Filter Service1. Remove the seat, release theair box cover clips, andremove the air box cover.2. Loosen

97MAINTENANCE AND LUBRICATIONLightsWhen servicing a halogen lamp, don’t touch the lamp with barefingers. Oil from your skin leaves a residue, causing