Polaris 2004 SPORTSMAN Owner'S Manual Download Page 137

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134

INDEX

Main Switch

. . . . . . . . . . . . . . . . . . . .

MAINTENANCE

AND LUBRICATION

69-111

. . . .

Maintenance Record

. . . . . . . . . . . . . .

Making Turns

. . . . . . . . . . . . . . . . . . .

Master Cylinder

. . . . . . . . . . . . . . . . .

Mode/Reverse Override Switch

. . . . .

Noise Emission Control System

. . . . .

Odometer

. . . . . . . . . . . . . . . . . . . . . .

Oil Change

. . . . . . . . . . . . . . . . . . . . .

Oil Change (400/500)

78-79

. . . . . . . . . .

Oil Change (600/700)

. . . . . . . . . . . . .

Oil Check

. . . . . . . . . . . . . . . . . . . . . .

Oil Filter Change

. . . . . . . . . . . . . . . .

Oil, Front Gearcase

. . . . . . . . . . . . . .

Oil Pump Priming

. . . . . . . . . . . . . . . .

Oil, Rear Gearcase (600/700)

. . . . . . .

Oil, Transmission (400/500)

. . . . . . . .

Oil, Transmission (600/700)

. . . . . . . .

OPERATION

50-67

. . . . . . . . . . . . . . . .

Operator Safety

11-35

. . . . . . . . . . . . . .

Parking Brake

. . . . . . . . . . . . . . . . . . .

Parking on an Incline

. . . . . . . . . . . . .

Periodic Maintenance Schedule

69-72

. .

POLARIS PRODUCTS

115

. . . . . . . . . . .

Pre-Ride Inspection

. . . . . . . . . . . . . .

Premium 4 Synthetic Lubricant

. . . . .

PVT Drying

102

. . . . . . . . . . . . . . . . . . .

PVT System

101-102

. . . . . . . . . . . . . . .

Radiator Coolant Level

. . . . . . . . . . .

Rear Gearcase Oil (600/700)

. . . . . . .

Rear Spring

112

. . . . . . . . . . . . . . . . . . . .

Reverse Override Switch

. . . . . . . . . .

Rider Information Center

46-49

. . . . . . .

Safe Riding Gear

. . . . . . . . . . . . . . . .

SAFETY

6-35

. . . . . . . . . . . . . . . . . . . . .

Safety Decals and Locations

6-9

. . . . . .

Safety Training

. . . . . . . . . . . . . . . . . .

Setting the Parking Brake

. . . . . . . . . .

Side Panel Removal

. . . . . . . . . . . . . .

Sidehilling

. . . . . . . . . . . . . . . . . . . . .

Spark Arrestor

100

. . . . . . . . . . . . . . . . .

Spark Plug Removal/Replacement

. . .

Spark Plugs

. . . . . . . . . . . . . . . . . . . . .

SPECIFICATIONS

120-127

. . . . . . . . . .

Starting a Cold Engine

. . . . . . . . . . . .

Starting a Warm Engine

. . . . . . . . . . .

Starting the Engine

53-54

. . . . . . . . . . . .

Steering Assembly

. . . . . . . . . . . . . . .

Stop Switch

. . . . . . . . . . . . . . . . . . . .

Storage

107-110

. . . . . . . . . . . . . . . . . . .

Storage Tips

108-110

. . . . . . . . . . . . . . .

Switches

. . . . . . . . . . . . . . . . . . . . . . .

TABLE OF CONTENTS

. . . . . . . . . . . .

Tachometer

. . . . . . . . . . . . . . . . . . . . .

Taillight/Brakelight

Lamp Replacement

. . . . . . . . . .

Throttle Cable Freeplay

114

. . . . . . . . . .

Throttle Lever

. . . . . . . . . . . . . . . . . . .

Tires

. . . . . . . . . . . . . . . . . . . . . . . . . .

Toe Alignment

. . . . . . . . . . . . . . . . . .

Transmission

. . . . . . . . . . . . . . . . . . .

Transmission Oil (400/500)

. . . . . . . .

Transmission Oil (600/700)

. . . . . . . .

Transporting the ATV

111

. . . . . . . . . . . .

Traveling Downhill

. . . . . . . . . . . . . .

Traveling Uphill

. . . . . . . . . . . . . . . . .

Trip Meter

. . . . . . . . . . . . . . . . . . . . .

TROUBLESHOOTING

116-119

. . . . . .

Turning Around on a Hill

. . . . . . . . . .

Spark Arrestor

. . . . . . . . . . . . . . . . . .

VEHICLE IDENTIFICATION

NUMBERS

. . . . . . . . . . . . . . . . . .

Vehicle Immersion

. . . . . . . . . . . . . . .

WARRANTY

128-132

. . . . . . . . . . . . . .

WELCOME

. . . . . . . . . . . . . . . . . . . . .

Wheel Installation

. . . . . . . . . . . . . . .

Wheel Nut Torque Specifications

. . . .

Wheel Removal

. . . . . . . . . . . . . . . . .

Summary of Contents for 2004 SPORTSMAN

Page 1: ......

Page 2: ...L Operate without proper training or instruction Operate on public roads A collision can occur with another vehicle Operate at speeds too fast for your skills or the conditions Use ALCOHOL or DRUGS be...

Page 3: ...wn to cause cancer birth defects or other reproductive harm A card containing important ATV safety information should be attached to the owner s manual on the next page If you cannot locate this card...

Page 4: ...ted a web site just for YOU S Technical tips S New product introductions S Event schedules S Parts and Service Manual information S Exciting details about The Way Out Check it out www polarisindustrie...

Page 5: ...uction components some minor discrepancies may result between the actual vehicle and the information presented in this publication Depictions and or procedures in this publication are intended for ref...

Page 6: ...t the finest machine we ve ever produced For safe and enjoyable operation of your vehicle be sure to follow the instructions and recommendations in this owner s manual Your manual contains instruction...

Page 7: ...hese numbers are essential to the recovery and identification of your vehicle Remove the spare key and store it in a safe place Your key can be duplicated only by mating a Polaris key blank with one o...

Page 8: ...ICLE IDENTIFICATION NUMBERS 4 SAFETY 6 CONTROLS 36 FEATURES 44 OPERATION 50 EMISSION CONTROL SYSTEMS 68 MAINTENANCE AND LUBRICATION 69 ADJUSTMENTS 112 POLARIS PRODUCTS 115 TROUBLESHOOTING 116 SPECIFIC...

Page 9: ...ls on the ATV If any decal becomes illegible or comes off contact your Polaris dealer to purchase a replacement Replacement safety decals are provided by Polaris at no charge The part number is printe...

Page 10: ...3 rear is best For stability on rough or hilly terrain reduce speed and cargo Do not block headlight Be careful if load extends over the side of the rack Read Owner s Manual for more detailed loading...

Page 11: ...njury or death NO STEP 7078689 WARNING S DO NOT TOW FROM RACK OR BUMPER Vehicle damage or tipover may result causing severe injury or death Tow only from tow hooks or hitch S Max Rack Loads Front 100...

Page 12: ...cause sudden in creases in pow er and traction if too much throttle is ap plied Loss of control or for ward flipover may result es pecially in AWD See Own er s Manual 7170911 TRAILER MAX WEIGHT 1225 L...

Page 13: ...stitute label ANSI z90 1 or the Snell Memorial Foundation label 2 Eye Protection Do not depend on sunglasses for proper eye protection A pair of goggles or a helmet face shield offer the best protecti...

Page 14: ...Polaris dealer you can request this free safety training from any authorized Polaris dealer A Polaris ATV is an off road vehicle Familiarize yourself with all laws and regulations concerning the oper...

Page 15: ...your vehicle or in this manual alerts you to the potential for personal injury The safety alert warning indicates a potential hazard that may result in serious injury or death The safety alert cautio...

Page 16: ...ves boots a long sleeved shirt or jacket and long pants S Never consume alcohol or drugs before or while operating an ATV S Never operate at excessive speeds Travel at speeds appropriate for the terra...

Page 17: ...er attempt to turn the ATV around on any hill until you ve mastered on level ground the turn ing technique outlined in this manual Avoid crossing the side of a steep hill when possible S Always use pr...

Page 18: ...ETY call the Con sumer Product Safety Commission at 1 800 638 2772 or call Polaris at 1 800 342 3764 Equipment Modifications We are concerned for the safety of our customers and for the general public...

Page 19: ...e operating techniques described in the owner s manual For more information about the training course contact an authorized ATV dealer or call Polaris at 1 800 342 3764 POTENTIAL HAZARD Failure to fol...

Page 20: ...the operator s ability to balance and control the ATV which could cause an accident and injury to the operator and or passenger HOW TO AVOID THE HAZARD Never carry a passenger The purpose of the long...

Page 21: ...ways WHAT CAN HAPPEN ATV tires are designed for off road use Operating on paved surfaces may adversely affect the handling of the ATV and could result in loss of control accident and or injury HOW TO...

Page 22: ...roads or highways WHAT CAN HAPPEN The ATV could collide with another vehicle HOW TO AVOID THE HAZARD Never operate the ATV on any public street road or highway including dirt and gravel roads In many...

Page 23: ...ases the risk of a severe head injury or death in the event of an accident Operating without eye protection could result in an accident and could increase the chance of a severe injury in the event of...

Page 24: ...an ATV could result in an accident causing severe injury or death HOW TO AVOID THE HAZARD Never consume alcohol or drugs before or while operating an ATV POTENTIAL HAZARD Operating the ATV at excessi...

Page 25: ...RD Attempting wheelies jumps and other stunts WHAT CAN HAPPEN Attempting stunts increases the chance of an accident including an overturn HOW TO AVOID THE HAZARD Never attempt wheelies jumps or other...

Page 26: ...cedures and schedules described in the owner s manual POTENTIAL HAZARD Removing hands from the handlebars or feet from the footrests during operation WHAT CAN HAPPEN Removing even one hand or foot can...

Page 27: ...on unfamiliar terrain WHAT CAN HAPPEN Unfamiliar terrain may contain hidden rocks bumps or holes that could cause loss of control or overturn HOW TO AVOID THE HAZARD Travel slowly and use extra cauti...

Page 28: ...y rough slippery or loose terrain could cause loss of traction or loss of control which could result in an accident or overturn HOW TO AVOID THE HAZARD Do not operate on excessively rough slippery or...

Page 29: ...ed in the owner s manual Practice turning at slow speeds before attempting to turn at faster speeds Never turn at excessive speed POTENTIAL HAZARD Operating on excessively steep hills WHAT CAN HAPPEN...

Page 30: ...r s manual Always check the terrain carefully before ascending any hill Never operate the ATV on hills steeper than 25_ Never climb hills with excessively slippery or loose surfaces Shift your weight...

Page 31: ...traveling down hills as described in the owner s manual NOTE A special technique is required when braking while traveling downhill See page 62 Always check the terrain carefully before descending a hi...

Page 32: ...n the ATV around on any hill until you ve mastered the turning technique on level ground as described in the owner s manual See page 63 Use extra caution when turning on any hill Avoid crossing the si...

Page 33: ...the brakes Lock the parking brake when fully stopped If the ATV begins rolling backwards Keep weight uphill Never apply engine power Never apply the rear brake while rolling backwards Apply the single...

Page 34: ...as rocks and fallen trees when possible If unavoidable use extreme caution and always follow proper procedures as outlined in the owner s manual POTENTIAL HAZARD Skidding or sliding WHAT CAN HAPPEN Sk...

Page 35: ...ght carefully avoid sudden movements and maintain a slow and steady forward motion Do not make sudden turns or stops and do not make sudden throttle changes Wet brakes may have reduced stopping abilit...

Page 36: ...e owner s manual and on safety decals POTENTIAL HAZARD Operating the ATV with improper modifications WHAT CAN HAPPEN Improper installation of accessories or modification of the ATV may cause changes i...

Page 37: ...ing cargo or pulling a trailer Allow a greater distance for braking Always follow the instructions in the owner s manual for carrying cargo or pulling a trailer POTENTIAL HAZARD Operating on frozen bo...

Page 38: ...es good judgement and physical skills Persons with cognitive or physical disabilities who operate this vehicle have an increased risk of overturn and loss of control which could result in severe injur...

Page 39: ...se is to provide the operator with a quick means of engine shutdown in case of an emergency Main Switch 3 To start the engine slide the stop switch to the center RUN position and turn the main key swi...

Page 40: ...y operating throttle controls could cause an accident and lead to severe injury or death Never start or operate an ATV with a sticking or improperly operating throttle Always contact your dealer for s...

Page 41: ...fore riding When squeezed the lever should feel firm Any sponginess would indicate a possible fluid leak or low master cylinder fluid level which must be corrected before riding Contact your dealer fo...

Page 42: ...hen checking the fluid level the ATV must be on level ground with the handlebars straight If the fluid level is low add DOT 3 brake fluid only See page 115 for the part numbers of Polaris products 1 2...

Page 43: ...guards S The parking brake may relax if left on for a long period of time Al ways block the wheels to prevent rolling S Always block the wheels on the downhill side of the ATV if leaving it parked on...

Page 44: ...ithout skidding Brake Fluid Level Check the brake fluid level frequently for the auxiliary brake system The reservoir is located under the seat or near the auxiliary brake Maintain the fluid level bet...

Page 45: ...It has two positions OFF For vehicle storage and when transporting ON For normal operation Fuel Tank The fuel tank filler cap 2 is located directly below the handlebar Use either leaded or unleaded g...

Page 46: ...t necessary to apply the brake Whenever the ATV is left unattended always place the transmission in PARK and lock the parking brake Belt Life To extend belt life use low forward gear in heavy pulling...

Page 47: ...s on See page 36 There is no limit to the length of time the vehicle may remain in AWD Engaging Front Gearcase The AWD switch may be turned on or off while the vehicle is moving Initially the vehicle...

Page 48: ...ed to approximately 7 9 mph Refer to page 36 for additional information 1 Rider Information Center 2 Speedometer needle in addition to showing vehicle speed the needle flashes when a warning condition...

Page 49: ...c Mode Indicator 5 Low Battery and Over Voltage This warning usually indicates that the ATV is being operated at an RPM too low to keep the battery charged A low battery warning may also occur under n...

Page 50: ...ATV Mode 2 Trip Meter The trip meter records the miles traveled by the ATV on each trip if it s reset before each trip To reset the trip meter select the trip meter mode Press and hold the mode button...

Page 51: ...and wait 10 seconds 2 Set the park brake and shift the transmission to neutral 3 Hold the mode reverse override button and turn the key switch on 4 Release the switch as soon as the display is activat...

Page 52: ...ash release the button The setting will increase by one hour each time the button is pressed Pressing and holding the button will allow the numbers to escalate much faster When the desired time increm...

Page 53: ...verfill the tank Do not fill the tank neck S If gasoline spills on your skin or clothing immediately wash it off with soap and water and change clothing S Never start the engine or let it run in an en...

Page 54: ...irst Select an open area that allows room to familiarize yourself with vehicle operation and handling 4 Vary the throttle positions Do not operate at sustained idle 5 Perform regular checks on fluid l...

Page 55: ...ne stop switch Check for proper function 7 Wheels Check for tightness of wheel nuts and axle nuts check that axle nuts are secured by cotter pins 8 Air cleaner element Check for dirt clean or replace...

Page 56: ...y past the ON position to engage the starter Activate the starter for a maximum of five seconds releasing the key when the vehicle starts If the engine does not start release the starter and wait five...

Page 57: ...over choked when warm depress the throttle lever fully while cranking to aid in starting 5 Release the throttle lever immediately after the engine starts If the engine does not start and all conditio...

Page 58: ...ications section of the owner s manual and on the safety decals Cargo weight should be evenly distributed 1 3 on the front rack and 2 3 on the rear rack and mounted as low as possible When operating o...

Page 59: ...conditions which could result in loss of control of the vehicle S OPERATE ONLY WITH STABLE AND SAFELY ARRANGED LOADS When handling off centered loads that cannot be centered securely fasten the load a...

Page 60: ...to warm up then shift the transmission into gear 3 Check your surroundings and determine your path of travel 4 Release the parking brake 5 Slowly depress the throttle with your right thumb and begin...

Page 61: ...the turn leaning your upper body to the inside of the turn while supporting your weight on the outer footrest This technique alters the balance of traction between the rear wheels allowing the turn to...

Page 62: ...ning the handlebars in the direction of the skid and shifting your body weight forward Severe damage to drive train may occur if the AWD is engaged while the wheels are spinning Always allow the rear...

Page 63: ...hrottle opening 6 Remain alert and be prepared to take emergency action This may include quick dismounting of the vehicle 25_ Maximum WARNING Braking and handling are greatly affected when operating i...

Page 64: ...eight toward the hill while keeping your feet on the footrests 3 Steer slightly into the hill to maintain vehicle directions NOTE If the vehicle begins to tip quickly turn the front wheel downhill if...

Page 65: ...your weight to the rear of the vehicle 3 Slow down 4 Apply the brakes slightly to aid in slowing Familiarize yourself with operation of the auxiliary brake in the event loss of normal service brakes o...

Page 66: ...service brake release the parking brake lock and slowly allow the vehicle to roll around to your right until it s pointing across the hill or slightly downward 6 Lock the parking brake and remount the...

Page 67: ...and rear gearcases and all grease fittings NOTE Avoid operating the vehicle through deep or fast flowing water If you cannot avoid water that exceeds the recommended maximum depth go slowly balance y...

Page 68: ...the terrain you re traveling on Be constantly alert for hazards such as logs rocks and low hanging branches Severe injury or death can result if your vehicle comes in contact with a hidden obstacle No...

Page 69: ...ncreased Do not operate at wide open throttle Open the throttle just enough to maintain a desired speed WARNING Failure to use caution when operating in reverse can result in serious injury or death B...

Page 70: ...ng on an incline if possible If it s unavoidable follow these precautions 1 Turn the engine off 2 Place the transmission in PARK 3 Set the parking brake 4 Always block the rear wheels on the downhill...

Page 71: ...0 1C Exhaust Emission Control System The exhaust emission control system is composed of efficient carburetor settings with an optimum ignition system Idle speed can be adjusted with the throttle stop...

Page 72: ...our Vehicles subjected to severe use such as operation in wet or dusty areas should be inspected and serviced more frequently Inspect clean lubricate adjust and replace parts as necessary When inspect...

Page 73: ...de Pre Ride Fill to proper levels Throttle Pre Ride Pre Ride Check operation Lights Pre Ride Pre Ride Check operation Engine stop switch Pre Ride Pre Ride Check operation Steering Pre Ride Pre Ride Ch...

Page 74: ...l change 100 hrs 1000 miles 6 months Check level daily break in service at one month change oil more often in cold weather L Oil Filter 100 hrs 1000 mi 6 months Replace with oil change L Engine breath...

Page 75: ...e Cooling system hoses 100 hrs 12 months Inspect J Clutches drive and driven 100 hrs 12 months Inspect clean Engine mounts 100 hrs 12 months Inspect J Brake fluid 200 hrs 24 months Change every two ye...

Page 76: ...CE AND LUBRICATION Periodic Maintenance Record Use the following chart to record periodic maintenance Maintenance Interval Performed Servicing Date Servicing Dealer or Person Remarks 10 hrs 20 hrs 50...

Page 77: ...level on dip stick Check level daily Brake Fluid DOT 3 Only Maintain level between fill lines See page 39 As required change every two years or 200 hours Transmission Oil Polaris Premium Synthetic Gea...

Page 78: ...75 MAINTENANCE AND LUBRICATION Lubrication Guide Fig 1 Fig 2 Fig 3...

Page 79: ...breakdown in ambient temperatures from 40 F to 120 F 40 to 49 C Its exceptional frictional properties result in more efficient operation more power output and lower fuel consumption Although Polaris...

Page 80: ...k is equipped with a lever lock 2 lift the lock to remove the dipstick 4 Reinstall the dipstick completely but do not lock it if equipped The dipstick must be completely seated to keep the angle and d...

Page 81: ...level surface Clean the area around the drain plug at the bottom of the oil tank and the bottom of the engine 2 Run the engine for two to three minutes then turn it off 3 Place a drain pan beneath th...

Page 82: ...mmended oil Reinstall the dipstick NOTE If the sump is not drained add about 1 3 4 quarts initially 13 Place the gear selector in neutral and set the parking brake 14 Prime the oil pump using the proc...

Page 83: ...to remove 9 Using a clean dry cloth clean the filter sealing surface on the crankcase 10 Lubricate the o ring on the new filter with a film of fresh engine oil Check to make sure the o ring is in good...

Page 84: ...the rear fender behind the wheel 1 Position the ATV on a level surface and remove the fill plug 2 Add the recommended oil as needed to bring the level to the bottom of the fill plug hole threads Oil...

Page 85: ...oducts Oil Check 1 Position the ATV on a level surface 2 Remove the fill plug 1 and view the oil level Maintain the oil level even with the bottom of the fill plug hole 3 Add the recommended gearcase...

Page 86: ...se Oil Check 1 To access the fill plug remove the four screws on the footwell and gently pull outward to remove the footwell 2 Remove the fill plug and check the oil level The oil should be maintained...

Page 87: ...and inspect the oil level through the fill plug hole 1 Maintain the oil level even with the bottom of the fill plug hole 3 Add the recommended gearcase oil as needed Oil Change 1 Place a drain pan be...

Page 88: ...diator past the pressure cap and into the recovery bottle As engine coolant temperature decreases the contracting cooled coolant is drawn back up from the tank past the pressure cap and into the radia...

Page 89: ...not allow the recovery system to function properly Contact your dealer for the correct replacement part NOTE To ensure that the coolant maintains its ability to protect the engine we recommend that t...

Page 90: ...ak is likely and the diaphragm should be replaced Always fill the reservoir as needed whenever the cover is loosened or removed to ensure proper diaphragm operation Use Polaris DOT 3 brake fluid Do no...

Page 91: ...anged when worn to 3 64 1 cm or about the thickness of a U S dime Auxiliary Brake The auxiliary brake system is intended to be used as a backup for the main brake system Should the main system fail th...

Page 92: ...f the rear tires on each side of the vehicle and goes around the stands in front of the vehicle 2 4 Measure the distance from the string to the rim at the front and rear of the front rim 3 Rear measur...

Page 93: ...utward to disengage the two rear tabs 3 Place your hand on top of the side panel behind the fuel tank With a quick and firm motion push down on the side panel to disengage the top rear two tabs Then p...

Page 94: ...e 4 Remove the wheel nuts and remove the wheel Operating your ATV with worn tires improperly inflated tires non standard tires or improperly installed tires will affect vehicle handling and could caus...

Page 95: ...eel nut torque specifications chart NOTE All nuts that have a cotter pin installed must be serviced by an authorized Polaris dealer Wheel Nut Torque Specifications Check the wheel nut torques occasion...

Page 96: ...se 1 To access the breather filter 3 remove the left side panel as outlined on page 90 The breather filter is on the hose that runs between the engine and air box 2 Remove the clamps and pull the filt...

Page 97: ...dometer Unplug the indicator light harness and remove the pod cover 6 Unplug the headlamp from the wiring harness Be sure to pull on the connector not on the wiring 7 Remove the boot and locking colla...

Page 98: ...headlight and make a mark on the wall at the same height 3 Start the engine and turn the headlight switch to high beam 4 Observe the headlight aim on the wall The most intense part of the headlight b...

Page 99: ...onnect the speedometer harnesses from the speedometer Unplug the indicator light harness and remove the pod cover 6 Unplug the headlamp from the wiring harness 7 Pull the headlight housing up to relea...

Page 100: ...ssembly into the headlight assembly Turn the headlight harness counterclockwise to secure the headlamp into place Taillight Brakelight Lamp Replacement If the taillight brakelight does not work the la...

Page 101: ...use of an improper spark plug or incorrect carburetion adjustments 2 Wet Fouled The wet fouled insulator tip is black A damp oil film covers the firing end There may be a carbon layer over the entire...

Page 102: ...Turn the engine over several times using the electric start 7 Dry the spark plug and reinstall or replace it with a new plug 8 Tighten the carburetor drain screw 9 Turn the fuel valve on 10 Attempt to...

Page 103: ...PARK and repeat steps 3 and 4 until no more particles are expelled when the engine is revved 6 Stop the engine and allow the arrestor to cool Reinstall the arrestor plug and remove the outlet cover or...

Page 104: ...above the engagement speed of 1200 1400 RPM However in high range at 3 MPH 5 KPH the engine would be running at only 1500 RPM Whenever operating this close to the engagement speed the engine may be r...

Page 105: ...G Failure to comply with the instructions in this warning can result in severe injury or death Do not modify any component of the PVT system Doing so may reduce its strength so that a failure may occu...

Page 106: ...lean shop towels Coat the terminals with dielectric grease or petroleum jelly Be careful not to allow cleaning solution or tap water into a conventional battery Battery electrolyte is poisonous It con...

Page 107: ...ructions and securely installed If not battery gases could accumulate and cause an explosion The tube should be routed away from the frame and body to prevent corrosion Avoid skin contact with electro...

Page 108: ...d Battery The following battery charging instructions apply only to the installation of a YUASA activated sealed battery Read all instructions before proceeding with the installation of this battery T...

Page 109: ...fore and 1 2 hours after the end of charging State of Charge Voltage Action Charge Time Using constant current charger standard amps specified on top of battery 100 12 8 13 0 volts None check at 3 mos...

Page 110: ...r body first and the lower parts last Rinse with water frequently and dry with a chamois to prevent water spots NOTE If warning and safety labels are damaged contact your a Polaris dealer for free rep...

Page 111: ...th in the fuel system Allow 15 20 minutes of operation for the stabilizer to disperse through the fuel in the tank and carburetor Turn the fuel valve off and drain the carburetor bowl Oil and Filter W...

Page 112: ...t the fuel system with Polaris Carbon Clean following the instructions on the can Run the engine for several minutes so the Carbon Clean reaches the carburetor Turn the engine off 2 Support the front...

Page 113: ...scharge Battery Tendert can be left connected during the storage period and will automatically charge the battery if the voltage drops below a pre determined point Check the fluid level monthly Batter...

Page 114: ...key to prevent loss during transporting 2 Place the transmission in PARK and lock the parking brake 3 Turn the fuel valve off and be sure the fuel cap oil cap and seat are installed securely 4 Always...

Page 115: ...four bolts 3 Adjust the handlebar to the desired height Be sure the handlebars do not contact the gas tank or any other part of the machine when turned fully to the left or right 4 Torque the front tw...

Page 116: ...des ranging from zero to 6 000 feet 1800 m and temperatures of 40 degrees F 4 degrees C or higher Above 6000 feet 1800 m the engine air fuel mixture becomes overly rich and the engine loses approximat...

Page 117: ...le adjuster sleeve 2 Loosen the adjuster locknut 3 2 Turn the adjuster until 1 16 to 1 8 freeplay is achieved at the thumb lever NOTE While adjusting freeplay be sure to flip the throttle lever back a...

Page 118: ...ase Oil 2871654 Premium Drive Hub Fluid 8 oz 2872277 Premium Drive Hub Fluid 2 5 gal Grease Specialized Lubricants 2871322 Premium All Season Grease 3 oz cartridge 2871423 Premium All Season Grease 14...

Page 119: ...for efficient enga gement Towing pushing at low RPM low ground speed Use low range only Utility use plowing snow dirt etc Use low range only Stuck in mud or snow Shift the transmission to low range an...

Page 120: ...the fuel system and refuel Fuel valve is turned off Turn the fuel valve on Old or non recommended fuel Replace with new fuel Fouled or defective spark plug s Inspect plug s replace if necessary No sp...

Page 121: ...e ignition connections Check all connections and tighten Water present in fuel Replace with new fuel Low battery voltage Recharge battery to 12 5 VDC Kinked or plugged fuel vent line Inspect and repla...

Page 122: ...voltage Recharge battery to 12 5 VDC Incorrect fuel Replace with recommended fuel Clogged air filter Inspect and clean or replace Reverse speed limiter malfunction See your Polaris dealer Electronic t...

Page 123: ...ter Dry Weight 697 lbs 316 kg Base model 739 lbs 335 kg New Break Up Shadow Hunter Minimum Turning Radius 65 in 165 cm Fuel Capacity 4 25 gal 16 l Engine Oil Capacity 2 qts 1 9 l Coolant Capacity 2 25...

Page 124: ...ion Progressive Rate with 9 5 24 1 cm of travel Shock Adjustment Rear Spring Preload Adjust Headlight 1 Single Beam on handlebar 50 w 2 Single Beam on grill 27 w Taillights 8 26 w Brakelight 26 9 w In...

Page 125: ...in 28 6 cm Dry Weight 697 lbs 316 kg HO 739 lbs 335 kg New Break Up Shadow Hunter Minimum Turning Radius 65 in 165 cm Fuel Capacity 4 25 gal 16 l Engine Oil Capacity 2 qts 1 9 l Coolant Capacity 2 25...

Page 126: ...Rate with 9 5 24 1 cm of travel Shock Adjustment Rear Spring Preload Adjust Headlight 1 Single Beam on Handlebar 50 w 2 Single Beam on Grill 27 w Taillights 8 26 w Brakelight 26 9 w Instrument Cluste...

Page 127: ...n 128 9 cm Ground Clearance 11 25 in 28 6 cm Dry Weight 740 lbs 336 kg Minimum Turning Radius 71 5 in 181 6 cm unloaded Engine Oil Capacity 2 qts 1 9 l Coolant Capacity 3 2 qts 3 l Engine EH059OLE024...

Page 128: ...ck Adjustment Rear Spring Preload Adjust Headlight watts 1 Single Beam on Handlebar 50 w 2 Single Beam on Grill 27 w Taillights 8 26 w Brake Light 26 9 w Instrument Cluster LCD Jetting Chart Altitude...

Page 129: ...se 50 75 in 128 9 cm Ground Clearance 11 25 in 28 6 cm Dry Weight 747 lbs 339 kg Minimum Turning Radius 76 in 193 cm unloaded Engine Oil Capacity 2 qts 1 9 l Coolant Capacity 3 2 qts 3 l Engine EH068O...

Page 130: ...Adjustment Rear Spring Preload Adjust Headlight 1 Single Beam on Handlebar 50 w 2 Single Beam on Grill 27 w Taillights 8 26 w Brake Light 26 9 w Instrument Cluster LCD Jetting Chart Altitude AMBIENT T...

Page 131: ...gistration Form must be completed by your dealer and submitted to Polaris within ten days Upon receipt of this registration Polaris will record the registration for warranty THE PURCHASER MUST COMPLET...

Page 132: ...rosion or defects in parts components or the ATV due to fire explosions or any other cause beyond Polaris control This warranty does not cover the use of unauthorized lubricants chemicals or fuels tha...

Page 133: ...egistration form to the dealer THE COST OF TRANSPORTATION TO AND FROM THE DEALER IS YOUR RESPONSIBILITY Polaris suggests that you use your original selling dealer however you may use any Polaris Servi...

Page 134: ...ling within the country where your vehicle was purchased Warranty or Service Bulletin repairs may be requested from any authorized Polaris dealer who sells the same line as your vehicle Outside the Co...

Page 135: ...d outside of the country where it was pur chased and you have not followed the procedure set out above your vehicle will no longer be eligible for warranty or service bulletin cover age of any kind Ve...

Page 136: ...Diagnostic Mode Instrumentation 48 49 Driving in Reverse 66 Driving on Slippery Surfaces 59 Driving Over Obstacles 65 Driving Procedures 57 Driving Safely 57 67 Driving Through Water 64 E Electrical...

Page 137: ...rmation Center 46 49 S Safe Riding Gear 10 SAFETY 6 35 Safety Decals and Locations 6 9 Safety Training 11 Setting the Parking Brake 40 S Side Panel Removal 90 Sidehilling 61 Spark Arrestor 100 Spark P...

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Polaris 2004 SPORTSMAN, Owner'S Manual

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Summary of Contents for 2004 SPORTSMAN

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