Polaris Sportsman 700 HO 2004 Owner'S Manual Download Page 137

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135

INDEX

Accessories

110

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

ADJUSTMENTS

114-116

. . . . . . . . . . .

Age Restrictions

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

Air Filter Service

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

All Wheel Drive

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

Automatic Transmission

. . . . . . . . . . .

Auxiliary Brake

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

AWD

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

Battery

107-109

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

Battery (Conventional)

106

. . . . . . . . . . .

Battery Charging (Sealed)

108-109

. . . .

Battery Fluid (Conventional)

108

. . . . . .

Battery Installation

107

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

Battery Removal

107

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

Battery Storage

108

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

Belt Life

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

Brake Fluid

39, 41

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

Brake Lever

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

Brake, Auxiliary

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

Brake, Front

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

Brake, Rear

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

Break-In Period

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

Breather Filter

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

Camber and Caster

114

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

Carburetor/Idle RPM

115

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

Choke

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

Cleaning

110-113

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

Clutching Chart (400)

123

. . . . . . . . . . .

Clutching Chart (500)

125

. . . . . . . . . . .

Clutching Chart (600)

127

. . . . . . . . . . .

Clutching Chart (700)

129

. . . . . . . . . . .

Cold Weather Operation

. . . . . . . . . . .

CONTROLS

36-43

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

Coolant Level

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

Cooling System

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

Crankcase Emission Control System

Diagnostic Mode

48-49

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

Driving in Reverse

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

Driving on Slippery Surfaces

. . . . . . .

Driving Over Obstacles

. . . . . . . . . . .

Driving Procedures

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

Driving Safely

57-67

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

Driving Through Water

. . . . . . . . . . .

Electrical Switches

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

EMISSION CONTROL SYSTEMS

. .

Engaging Front Gearcase

. . . . . . . . . .

Engine Cooling System

. . . . . . . . . . .

Engine Stop Switch

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

Exhaust Emission Control System

. . .

Equipment Modifications

. . . . . . . . . .

FEATURES

44-49

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

Filter Systems

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

Front Gearcase Oil (400/500)

. . . . . . .

Front Gearcase Oil (600/700)

. . . . . . .

Front Wheel Hub Tightening

. . . . . . .

Fuel Filter

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

Fuel Safety

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

Fuel Tank

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

Fuel Valve

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

Gear Selector

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

Handlebars

114

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

Hauling Cargo

55-56

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

Headlamp Removal/Installation

100

. . . .

Headlight Housing Replacement

. . . .

Headlight Lamp Replacement

. . . . . .

High Beam Adjustment

. . . . . . . . . . .

High Range

104

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

Hour Meter

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

Instrument Cluster

45-49

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

Jetting/Clutching (400)

123

. . . . . . . . . .

Jetting/Clutching (500)

125

. . . . . . . . . .

Jetting/Clutching (600)

127

. . . . . . . . . .

Jetting/Clutching (700)

129

. . . . . . . . . .

K-turn

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

Light Switches

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

Lights

97-100

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

Low Range

104

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

Lubrication Guide

76-77

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

Summary of Contents for Sportsman 700 HO 2004

Page 1: ......

Page 2: ...own 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 or if it has been removed please call 1 800 342 3764 for assistance ...

Page 3: ...ated 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 polarisindustries com owner ...

Page 4: ...ing Polaris Industries Inc reserves the right to make product changes and improvements that may affect illustrations or explanations No part of this manual shall be reproduced or used without the written permission of Polaris Industries Inc Copyright 2002 Polaris Industries Inc All Rights Reserved Printed in the U S A ...

Page 5: ...it 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 instructions for minor maintenance but information about major repairs is outlined in the Polaris Service Manual and should be performed only by a Factory Certified Master Service Dealer MSD Technician Your Pol...

Page 6: ...these 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 of your existing keys If both keys are lost the ignition switch must be replaced See your Polaris dealer NOTE Record your vehicle s ID numbers and key number 3 in the spaces provided 2 1 31XX 3 2 400 ...

Page 7: ...CLE IDENTIFICATION NUMBERS 4 TABLE OF CONTENTS 5 SAFETY 6 CONTROLS 36 FEATURES 44 OPERATION 50 EMISSION CONTROL SYSTEMS 68 MAINTENANCE AND LUBRICATION 69 TROUBLESHOOTING 117 POLARIS PRODUCTS 121 SPECIFICATIONS 122 WARRANTY 130 INDEX 135 ...

Page 8: ...le on HILLS steeper than 25 degrees 25 To prevent flipover on hilly terrain when going up or down use throttle and brakes gradually DREVERSE operation can be dangerous even at low speeds Steering becomes difficult To prevent flipover avoid sudden braking or sharp turns DUse OVERRIDE for reverse speed limiter with caution To prevent loss of control never activate override button with open throttle ...

Page 9: ... 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 information WARNING 7079084 WARNING 7077920 ATTENTION S Operation of this vehicle without the air filter element will severely damage the engine S Clean pre filter element often more frequent cleaning requi...

Page 10: ...injury 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 lbs 45 kg Rear 200 lbs 91 kg 7170912 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 Fro...

Page 11: ...ause 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 MANUFACTURED BY POLARIS IND INC DATE VIN THIS VEHICLE IS AN ALL TERRAIN VEHICLE AND IS NOT INTENDED FOR USE ON PUBLIC ROADS 7078470 CE VÉHICULE EST UN VÉHICULE TOUT TERRAIN QUI NEST PAS DESTINE A ETRE UTILISE SUR LES CHEMINS PUBLICS C...

Page 12: ...nstitute 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 protection for your eyes They should be kept clean and be of shatterproof design bearing the markings z2 1 or VESC 8 3 Gloves Off road style gloves with knuckle pads are the best for comfort and protection 4...

Page 13: ...olaris 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 operation of this vehicle in your area We strongly advise you to strictly follow the recommended maintenance program outlined in your owner s manual This preventive maintenance program is designed to ensure...

Page 14: ...n 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 caution indicates a potential hazard that may result in minor personal injury or damage to the vehicle CAUTION NOTE A note will alert you to important information or instructions A caution indicates a situ...

Page 15: ...oves 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 terrain visibility and operating conditions and your experience S Never attempt wheelies jumps or other stunts S Always inspect your ATV before each use to make sure it s in safe operating condition Alway...

Page 16: ...ver 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 proper procedures if you stall or roll backwards while climbing a hill To avoid stalling maintain a steady speed when climbing a hill If you stall or roll backwards follow the special procedure for bra...

Page 17: ...FETY 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 Therefore we strongly recommend that consumers do not install on a Polaris ATV any equipment that may increase the speed or power of the vehicle or make any other modifications to the vehicle for th...

Page 18: ...he 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 follow the age recommendations for this ATV WHAT CAN HAPPEN Severe injury and or death could occur if a child under the minimum age recommendation operates an ATV Even though a child may be within the r...

Page 19: ...s 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 seat is to allow the operator to shift position as needed during operation It is not intended for carrying passengers WARNING ...

Page 20: ...eways 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 AVOID THE HAZARD Avoid operating the ATV on pavement If it s unavoidable travel slowly and avoid sudden turns or stops WARNING ...

Page 21: ... 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 states it s illegal to operate ATVs on public streets roads and highways WARNING ...

Page 22: ...eases 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 an accident HOW TO AVOID THE HAZARD Always wear an approved helmet that fits properly Always wear eye protection goggles or face shield gloves boots long sleeved shirt or jacket and long pants WARNI...

Page 23: ...g 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 excessive speeds WHAT CAN HAPPEN Excessive speed increases the operator s chance of losing control of the ATV which can result in an accident causing severe injury or death HOW TO AVOID THE HAZARD Always op...

Page 24: ...ARD 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 stunts Avoid exhibition driving WARNING ...

Page 25: ...ocedures 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 reduce ability to control the vehicle or could cause loss of balance and ejection from the ATV If the operator s foot is not firmly planted on the footrest it could come into contact with the rear w...

Page 26: ...V 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 caution when operating on unfamiliar terrain Always be alert to changing terrain conditions WARNING ...

Page 27: ...ly 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 loose terrain until you ve learned and practiced the skills necessary to control the ATV on such terrain Always use extra caution on rough slippery or loose terrain WARNING ...

Page 28: ...bed 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 The vehicle may overturn HOW TO AVOID THE HAZARD Never operate on hills too steep for the ATV or for your abilities Never operate the ATV on hills steeper than 25_ Practice on smaller hills before at...

Page 29: ...er 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 forward Never open the throttle suddenly while traveling uphill The ATV could flip over backwards Never go over the top of any hill at high speed An obstacle a sharp drop or another vehicle or person...

Page 30: ... 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 hill Shift your weight backward Never travel down a hill at high speed Avoid traveling down a hill at an angle which would cause the vehicle to lean sharply to one side Travel straight down the hill wh...

Page 31: ...rn 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 side of a steep hill When crossing the side of a hill Always follow proper procedures as described in the owner s manual Avoid hills with excessively slippery or loose surfaces Shift your weight to the...

Page 32: ... 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 lever brake gradually When fully stopped apply the rear brake as well and then lock the parking brake Dismount on uphill side or to either side if ATV is pointed straight uphill Turn the ATV around ...

Page 33: ... 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 Skidding or sliding can cause loss of control If the tires regain traction unexpectedly the ATV could overturn HOW TO AVOID THE HAZARD On slippery surfaces such as ice travel slowly and use extra cauti...

Page 34: ...ight 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 ability Always test the brakes after leaving water If necessary apply them several times to let friction dry out the pads POTENTIAL HAZARD Improperly operating in reverse WHAT CAN HAPPEN The ATV could coll...

Page 35: ...he 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 in handling which could lead to an accident HOW TO AVOID THE HAZARD Never modify the ATV through improper installation or use of accessories All parts and accessories added to the vehicle must be genu...

Page 36: ...ying 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 bodies of water WHAT CAN HAPPEN Severe injury or death can result if the ATV and or the operator fall through the ice HOW TO AVOID THE HAZARD Never operate the ATV on a frozen body of water If you re c...

Page 37: ... to brakes throttle and steering systems Safe operation of this rider active vehicle requires 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 injury or death CAUTION Exposure to the hot components could result in a fire Always keep combustible materials aw...

Page 38: ...Its purpose 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 switch clockwise past the ON position Release the key when the engine starts NOTE Both the main switch and the emergency engine stop switch will shut off all electrical power to the vehicle incl...

Page 39: ...ly 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 service if throttle problems arise Failure to check or maintain proper operation of the throttle system can result in an accident if the throttle lever sticks during operation Always check the lever f...

Page 40: ...efore 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 for proper diagnosis and repairs Operating the ATV on streets or roads especially in darkness could result in an accident and serious injury or death Your ATV is not equipped with highway approved ligh...

Page 41: ...When 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 121 for the part numbers of Polaris products 1 2 After opening a bottle of brake fluid always discard any unused portion Never store or use a partial bottle Brake fluid is hygroscopic meaning it rapidly absorbs moisture from the air The moisture c...

Page 42: ... Important Safeguards 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 a hill Another option is to park the ATV in a sidehill position S Never depend on the parking brake alone if the ATV is parked on a hill Always block the wheels to prevent rolling Opera...

Page 43: ...without 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 between the maximum and minimum marks Aggressively applying the auxiliary brake when backing down a hill may cause rear tipover which could result in serious injury or death Use caution when applying th...

Page 44: ...ly is exhausted NOTE There s about a 7 to 10 mile 11 2 to 16 km range on reserve gas Always refill the gas tank as soon as possible after using the main supply Always return the valve to the on position after refueling Fuel Tank The fuel tank filler cap 2 is located directly below the handlebar Use either leaded or unleaded gasoline with a minimum pump octane number of 87 R M 2 octane Fuel Filter ...

Page 45: ...irst gear or in PARK if equipped and lock the parking brake Maintaining shift linkage adjustment is important to assure proper transmission function on the Sportsman 400 and 500 See your dealer if you experience any shifting problems Belt Life To extend belt life use low forward gear in heavy pulling situations and when operating at less than seven miles per hour for extended periods of time H L N...

Page 46: ...e 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 s electronic system will not enable the AWD until the engine RPM is below 3100 Once enabled the AWD remains enabled until the AWD switch is turned off If the switch is turned off while the front gearcase is ...

Page 47: ...that limits the ATV s speed 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 exists 3 Speedometer 2 3 1 CAUTION To prevent damage wash the ATV by hand or with a garden hose using mild soap Do not use alcohol to clean the instrument cluster Immediately...

Page 48: ...r illuminates when the electrical portion of the AWD system is enabled 3 Engine Hour Display Indicator 4 Service Interval Diagnostic 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 normal operation if the machine is at idle and high electrical load li...

Page 49: ...d by the 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 override button until the total changes to 0 NOTE In the Rider Information Center the trip meter display contains a decimal point but the odometer displays without a decimal point Mode 3 Hou...

Page 50: ... 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 activated The initial screen display refers to the software version installed in your ATV This information is displayed briefly Use the mode reverse override button to toggle through the diagnostic screens ...

Page 51: ...lash 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 increment is displayed release the button and wait for the wrench to stop flashing When the wrench stops blinking your service hours are set NOTE If you scroll past the intended number hold the button down...

Page 52: ...overfill 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 enclosed area Engine exhaust fumes are poisonous and can cause loss of con sciousness or death in a short time S Turn the fuel valve off whenever the ATV is stored or parked The engine exhaust from thi...

Page 53: ...first 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 levels controls and areas outlined on the daily pre ride inspection checklist See page 52 6 Pull only light loads 7 During the break in period change both the oil and the filter at 20 hours or 200 mil...

Page 54: ...ine 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 9 Steering Check for free operation noting any unusual looseness in any area 10 Loose parts Visually inspect the vehicle for any damaged components or loose nuts bolts or fasteners 11 Riding gear Wea...

Page 55: ... ignition key 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 seconds Activate the starter for another five seconds if necessary Repeat this procedure until the engine starts 6 If the engine slows or stops position the choke knob half way in to allo...

Page 56: ... the engine is 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 conditions are favorable change the spark plug and try again Cold Weather Operation If the ATV is used year round check the oil level frequently A rising oil level could indicate the accumulatio...

Page 57: ...fications 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 over rough or hilly terrain reduce speed and cargo weight to maintain stable driving conditions Do not obstruct the headlight beam with cargo Belt Life Use low forward gear when hauling or towing heav...

Page 58: ... 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 and operate with extra caution Always attach the tow load to the hitch point designated for your vehicle S HEAVY LOADS CAN CAUSE BRAKING AND CONTROL PROBLEMS Use extreme caution when applying brakes w...

Page 59: ...t 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 driving Vehicle speed is controlled by the amount of throttle opening 6 Drive slowly Practice maneuvering and using the throttle and brakes on level surfaces ...

Page 60: ... 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 be made smoothly The same leaning technique should be used for turning in reverse NOTE Practice making turns at slow speeds before attempting to turn at faster speeds WARNING Turning at sharp angles...

Page 61: ... and shifting your body weight forward 4 Driving with All Wheel Drive engaged can assist in controlling the vehicle in slippery areas Severe damage to drive train may occur if the AWD is engaged while the wheels are spinning Always allow the rear wheels to stop spinning before engaging the AWD CAUTION WARNING Failure to exercise care when operating on slippery surfaces can result in loss of tire t...

Page 62: ...throttle 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 in hilly terrain Improper procedure could cause loss of control or overturn and result in serious injury or death Avoid climbing steep hills 25_ maximum Use extreme caution when operating on hills and...

Page 63: ...ward 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 possible or dismount on the uphill side immediately Improperly crossing hills or turning on hills can result in loss of control or vehicle overturn resulting in severe injury or death Avoid crossing the side ...

Page 64: ... 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 occurs Excessive speed can cause loss of control and lead to serious injury or death Always operate slowly when traveling downhill WARNING ...

Page 65: ... 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 vehicle from the uphill side keeping body weight uphill 7 Restart the engine with the transmission still in forward 8 Release the parking brake and proceed slowly controlling speed with the service ...

Page 66: ... 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 your weight 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 If your vehicle becomes immersed and...

Page 67: ... 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 Not all obstacles are immediately visible Travel with caution in unfamiliar terrain WARNING ...

Page 68: ...increased 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 Before shifting into reverse always check for obstacles or people behind the vehicle When it s safe to proceed back slowly Do not use the override switch unless additional power is required for vehicl...

Page 69: ...cline if possible If it s unavoidable follow these precautions 1 Turn the engine off 2 Place the transmission in low range or park if equipped 3 Set the parking brake 4 Always block the rear wheels on the downhill side as shown in the illustration 5 Shut off the fuel supply ...

Page 70: ...engine air induction system 3 Replacement of any vehicle parts with parts not in compliance with federal regulations 4 Lack of proper maintenance USFS Approved Spark Arrestor Your Polaris ATV has a muffler that was tested and approved in accordance with the USFS Forest Service Standard 5100 1A Exhaust Emission Control System The exhaust emission control system is composed of efficient carburetor s...

Page 71: ...hour 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 inspection reveals the need for replacement parts use genuine Polaris parts available from your Polaris dealer NOTE Service and adjustments are critical If you re not familiar with safe service and adjustme...

Page 72: ...Air filter Pre cleaner Pre Ride Pre Ride Inspect clean Coolant level Pre Ride Pre Ride Replace coolant every two years Fuel tank and engine oil Pre Ride 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 Check for free operation More often under severe use...

Page 73: ...n oil level 20 hrs Monthly Inspect monthly change annually Battery 20 hrs Monthly Check terminals clean check fluid level if applica ble L Engine breather filter 20 hrs Monthly Inspect replace annually and as needed J Brake pad wear 10 hrs Monthly Inspect periodically Front and rear gearcase oil 100 hrs Monthly Check monthly change annually General lubrication 50 hrs 3 months Lubricate all fitting...

Page 74: ... hrs 6 months Inspect replace as needed Steering 50 hrs 6 months Inspect daily lubricate Front suspension 50 hrs 6 months Inspect lubricate tighten fasteners Rear suspension 50 hrs 6 months Inspect tighten fasteners Drive chain s 50 hrs 6 months Inspect daily adjust and lu bricate if needed L Spark plug 100 hrs 12 months Inspect replace as needed More often under severe use such as dirty or wet co...

Page 75: ...100 hrs 12 months Replace annually Radiator 100 hrs 12 months Inspect clean external sur face Cooling system hoses 100 hrs 12 months Inspect Spark arrestor 100 hrs 12 months Clean out 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 years J Front wheel bear ings 300 hrs 36 months Inspect replace as ...

Page 76: ...NCE 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 hrs 100 hrs ...

Page 77: ...75 NOTES ...

Page 78: ...ck 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 Fig 1 Polaris Premium Synthetic Gear case Lube See page 83 400 500 or page 85 600 700 Check every 6 months 1000 miles Change annually or at 100 hours Front Gear case Oil Fig 2 Premium Drive Hub Fluid See page 84 400 500 or page 86 600 700 Change annua...

Page 79: ...77 MAINTENANCE AND LUBRICATION Lubrication Guide Fig 1 Fig 4 Fig 2 Fig 3 Fig 5 Fig 1 Fig 2 Fig 6 ...

Page 80: ...l 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 Premium 4 is the only oil recommended for use in this engine use of any API certified SH oil is allowable as long as it s 0W 40 Oil may need to be changed more frequently if Polaris Premium 4 is not ...

Page 81: ...quipped 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 screwed completely in to keep the angle and depth of the stick consistent 5 Remove the dipstick and check the oil level Maintain the oil level in the normal or safe range 3 depending on the style of dipstick in your model Do not overfill 6 After r...

Page 82: ...a 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 the oil tank and remove the drain plug 1 Allow the oil to drain completely 4 Install a new sealing washer 2 on the oil drain plug NOTE The sealing surfaces on the drain plug and the oil tank should be ...

Page 83: ...n the drain plug and crankcase should be clean and free of burrs nicks or scratches 11 After draining reinstall the drain plug 12 Remove the dipstick 2 and add two quarts 1 9 l of the recommended 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 Start the engine and let it idle for one to t...

Page 84: ... 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 condition 11 Install the new filter and turn by hand until the filter gasket contacts the sealing surface then turn and additional 1 2 turn 12 Remove the dipstick and fill the sump with two quarts 1...

Page 85: ...e Remove the fill plug dipstick and wipe it clean 2 Reinstall the dipstick completely then remove it and check the level Add the recommended oil as needed to bring the level into the safe operating range 2 Oil Change 1 Remove the fill plug dipstick 2 Remove the transmission drain plug 3 It s located on the bottom of the gearcase 3 Drain the oil into a drain pan and dispose of properly 4 Clean and ...

Page 86: ...n the ATV on a level surface 2 Remove the fill plug 1 and view the lubricant level Lubricant should be kept level with the bottom of the fill plug threads 3 Add the recommended lubricant as needed to bring the oil to the proper level Oil Change 1 Position the vehicle on a level surface and remove the fill plug 2 Place a drain pan beneath the gearcase remove the gearcase drain plug and drain the oi...

Page 87: ...well and gently pull outward to remove the footwell 2 Remove the fill plug and check the oil level The oil should be maintained 1 5 8 from the top of the fill plug hole Oil Change 1 Remove the four screws on the footwell and gently pull outward to remove the footwell 2 Remove the transmission drain plug 2 which is located on the bottom left hand side Drain the oil into a drain pan and dispose of p...

Page 88: ...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 oil as needed Oil Change 1 Position the vehicle on a level surface and remove the fill plug 2 Place a drain pan beneath the gearcase remove the gearcase drain plug located on the bottom right hand side and drain the oil 3 Clean and ...

Page 89: ...g 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 beneath the drain and remove the drain plug 2 Catch and discard used oil properly 2 Clean and reinstall the drain plug with a new sealing washer Torque to 14 ft lbs 19 Nm 3 Remove the fill plug and add...

Page 90: ...adiator 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 radiator NOTE Some coolant level drop on new machines is normal as the system is purging itself of trapped air Observe coolant levels and maintain as recommended by adding coolant to the recovery bottle P...

Page 91: ...l 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 the system be completely drained every two years and a fresh mixture of antifreeze and water added Polaris recommends the use of Polaris Premium 60 40 anti freeze coolant or a 50 50 mixture of high qu...

Page 92: ...lways fill the reservoir as needed whenever the cover is loosened or removed to ensure proper diaphragm operation Use Polaris DOT 3 brake fluid see page 121 2 Check the brake system for fluid leaks 3 Check the brakes for excessive travel or spongy feel 4 Check the friction pads for wear damage and looseness 5 Check the security and surface condition of the disc NOTE Pads should be changed when wor...

Page 93: ...3 64 1 cm which is about the thickness of a U S dime Inspect the brake disc spline and pad wear surface for excessive wear Auxiliary Brake Your auxiliary brake is intended to be used as a backup for the main brake system Should the main system fail the rear brake can be activated by depressing the foot pedal on the inside of the right footrest The hydraulic auxiliary brake system will not require ...

Page 94: ...of 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 measurement should be 1 16 1 8 2 to 3 cm more than the front measurement NOTE If you discover improper alignment see your Polaris dealer for service Steering Assembly The steering assembly of the ATV shoul...

Page 95: ...outward 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 pull up on the side panel to disengage the front upper and lower tabs 4 To reinstall the side panel align the panel tabs with the slots on the front cab Push the panel upward and forward until the tab...

Page 96: ...ootrest frame 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 cause an accident resulting in serious injury or death Maintain proper tire pressure as described on the decal on your ATV and in the owner s manual Always use original equipment size and type...

Page 97: ...ing to the wheel 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 occasionally and when they ve been loosened for maintenance service Bolt Size Sportsman 400 500 Sportsman 600 700 Front 3 8 20 ft lbs 27 Nm 30 ft lbs 41 Nm Rear 3 8 20 ft lbs 27 Nm 30 ft lbs 41 N...

Page 98: ...ose 1 To access the breather filter 3 remove the left side panel as outlined on page 93 The breather filter is on the hose that runs between the engine and air box 2 Remove the clamps and pull the filter out of the hoses NOTE It s not necessary to remove the lower hose from the engine 3 Inspect the filter for debris Blow gently through the filter in the direction of the arrow to check for clogging...

Page 99: ...edometer 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 collar from the back of the lamp housing 8 Grasp the base of the lamp and lift it out 9 Reverse the previous steps to replace the lamp and reassemble the pod Apply dielectric grease to the light bulb sock...

Page 100: ...t 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 beam should be aimed two inches 5 1 cm below the mark placed on the wall NOTE Include rider weight on the seat when measuring 5 Adjust the beam to the desired position by turning the adjustment knob either cloc...

Page 101: ...nesses from the speedometer Unplug the indicator light harness and remove the pod cover 6 Unplug the headlamp from the wiring harness 7 Remove the o ring 1 from the headlight pivot pins 8 Pull the headlight housing up to release from the locking tabs 9 Lift the adjusting knob up to remove from the locking tabs 10 Carefully pull the assembly up and out of pod 11 Reverse the steps to install the new...

Page 102: ...assembly 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 lamp may need to be replaced 1 Remove the taillight lens cover mounting screws 1 Remove the lens cover 2 and gasket and set aside for reassembly 2 Remove the lamp 3 and replace it with a new lamp 3 Tes...

Page 103: ...white insulator tip indicates overheating caused by 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 nose Generally the electrodes are not worn General causes of fouling are excessive oil use of non recommended oil improper use of the choke or incor...

Page 104: ...6 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 start the engine If necessary repeat the drying procedure 11 Take the ATV to your dealer for service as soon as possible whether you succeed in starting it or not NOTE If water has been ingested in...

Page 105: ...arking brake and block the wheels Make sure the vehicle is in neutral or PARK if equipped 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 plug WARNING Failure to heed the following warnings while servicing the spark arrestor could result in serious inj...

Page 106: ...l 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 running at a speed too low to provide the pinch needed to prevent belt slip Belt slip is responsible for creating the excessive heat that destroys belts and causes outer clutch covers to fail By switc...

Page 107: ...NG 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 occur at a high speed The PVT system has been precision balanced Any modification will cause the system to be out of balance creating vibration and additional loads on components The PVT system rotates a...

Page 108: ... petroleum jelly Be careful not to allow cleaning solution or tap water into the battery Battery electrolyte is poisonous It contains sulfuric acid Serious burns can result from contact with skin eyes or clothing Antidote External Flush with water Internal Drink large quantities of water or milk Follow with milk of magnesia beaten egg or vegetable oil Call physician immediately Eyes Flush with wat...

Page 109: ...tructions 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 electrolyte which can cause severe burns 3 First connect and tighten the red positive cable 4 Second connect and tighten the black negative cable 5 Reinstall the battery cover and attach the hold down strap...

Page 110: ...ed 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 The YUASA activated sealed battery is already filled with electrolyte and has been sealed and fully charged at the factory Do not ever pry the sealing strip off or add any other fluid to this battery ...

Page 111: ...efore 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 from date of manufacture None required 75 100 12 5 12 8 volts May need slight charge if no charge given check in 3 months 3 6 hours 50 75 12 0 12 5 volts Needs Charge 5 11 hours 25 50 11 5 12 0 volt...

Page 112: ...er 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 replacement Polaris does not recommend the use of a high pressure type car wash system for washing the ATV If a high pressure system is used exercise extreme care to avoid water damage to the wheel bear...

Page 113: ...wth 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 Warm the engine and change the oil and filter Air Filter Air Box Inspect and clean or replace the pre cleaner and air filter Clean the air box and drain the sediment tube Breather Filter Inspect and c...

Page 114: ...at 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 end of the machine so the engine is level or tilted slightly rearward 3 Remove the spark plug Rotate the piston to BDC and pour approximately two ounces of recommended oil into the cylinder 4 Reinsta...

Page 115: ...Sealed Remove the battery and recharge it as outlined on page 108 Store the battery in a cool dry place Engine Anti Freeze Test engine coolant strength and change if necessary Coolant should be replaced every two years Storage Area Covers Set the tire pressure and safely support the ATV with the tires 1 2 off the ground Be sure the storage area is well ventilated and cover the machine with a genui...

Page 116: ... 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 two bolts to 10 12 ft lbs 14 17 Nm then torque the rear two bolts A gap of up to 1 8 will remain at the rear bolts 1 Improper adjustment of the handlebars or incorrect torquing of the adjuster block ti...

Page 117: ...udes 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 approximately 3 of its power for each 1000 foot 304 8 m increase in elevation Although this power cannot be regained adjustments to the carburetor and drive system can be made to allow more efficient operation...

Page 118: ...ble 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 and forth 3 Tighten the locknut and slide the boots over the cable adjuster until they touch at the midpoint of the adjuster 1 2 1 3 ...

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 and carefully use fast aggressive throttle application to engage clutch WARNING Excessive throttle may cause loss of control and vehicle overturn Climbing over large ob jects from a stopped posi tion S...

Page 120: ...t in fuel Drain 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 spark to spark plug Inspect plug s verify stop switch is on Crankcase filled with water or fuel Immediately see your Polaris dealer Overuse of choke Inspect clean and or replace spark plu...

Page 121: ...se 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 replace Incorrect fuel Replace with recommended fuel Clogged air filter Inspect and clean or replace Reverse speed limiter malfunction See your Polaris dealer Electronic throttle control malfunction See y...

Page 122: ...en Low battery 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 throttle control malfunction See your Polaris dealer Other mechanical failure See your Polaris dealer Overheated engine Clean radiator screen and core Clean engine exterior See your Pola...

Page 123: ... 2 5 gal 2870465 Oil Pump for Gearcase 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 oz cartridge 2871460 Starter Drive Grease 2871515 Premium U Joint Lube 3 oz 2871551 Premium U Joint Lube 14 oz 2871312 Grease Gun Kit 2871329 Dielectric Grease Nyog...

Page 124: ... 11 in 27 9 cm Dry Weight 697 lbs 316 kg Minimum Turning Radius 65 in 165 cm Fuel Capacity 4 75 gal 18 l Engine Oil Capacity 2 qts 1 9 l Coolant Capacity 3 2 qts 3 02 l Engine EH42PLE05 Displacement 425 Bore x Stroke 87 9 x 70 Pilot Jet 40 Main Jet 167 5 Needle Jet Q 0 829 Jet Needle 4GAC33 3 Pilot Screw 2 3 4 turn taper 12 5 Alternator Output 250 w Compression Ratio 9 2 Full Stroke Carburetor BST...

Page 125: ...7 Rear Suspension Full independent with anti roll bar 9 5 Shock Adjustment CAM Headlight 1 Single Beam on handlebar 50 w 2 Single Beam on grill 27 w Taillights 8 26 w Brakelight 26 9 w Instrument Cluster LCD Jetting and Clutching Charts Sportsman 400 Altitude AMBIENT TEMPERATURE Below 40 F Below 5 C 40 F and above 5 C and above Meters Feet 0 1800 0 6000 172 5 167 5 1800 3700 6000 12000 165 160 Alt...

Page 126: ...47 in 119 4 cm Wheelbase 50 5 in 128 3 cm Ground Clearance 11 in 27 9 cm Dry Weight 697 lbs 316 kg Minimum Turning Radius 65 in 165 cm Fuel Capacity 4 75 gal 18 l Engine Oil Capacity 2 qts 1 9 l Coolant Capacity 3 2 qts 3 02 l Engine EH50PLE13 Displacement 498 Bore x Stroke 92 x 75 Pilot Jet 40 Main Jet 152 5 Needle Jet X 6M 896 Jet Needle 6MGH1 94 3 Pilot Screw 2 Turn Alternator Output 250 w Comp...

Page 127: ...ension Progressive rate full independent with anti roll bar 9 5 Shock Adjustment CAM Headlight 1 Single Beam on Handlebar 50 w 2 Single Beam on Grill 27 w Taillights 8 26 w Brakelight 26 9 w Instrument Cluster LCD Jetting and Clutching Charts Sportsman 500 Altitude AMBIENT TEMPERATURE Below 40 F Below 5 C 40 F and above 5 C and above Meters Feet 0 1800 0 6000 157 5 152 5 1800 3700 6000 12000 150 1...

Page 128: ...ase 50 75 in 128 9 cm Ground Clearance 11 in 27 9 cm Dry Weight 740 lbs 336 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 EH059OLE021 Displacement 597 Bore x Stroke 76 5 x 65 Pilot Jet 45 Main Jet 155 Needle Jet P 4 Jet Needle J8 4FA01 3 Pilot Screw 1 5 Alternator Output 300 Watts 3000 rpm Compression Ratio 10 3 1 Starting Syste...

Page 129: ...50 2 Single Beam on Grill 27 Taillights watts 8 26 Brake Light watts 26 9 Instrument Cluster LCD Jetting and Clutching Charts Sportsman 600 Altitude AMBIENT TEMPERATURE Below 40 F Below 5 C 40 F and above 5 C and above Meters Feet 0 1800 0 6000 162 5 155 1800 3700 6000 12000 150 145 Altitude Shift Weight Drive Clutch Spring Driven Clutch Spring Helix Meters Feet 0 1800 0 6000 10 MH PN 5630513 Blue...

Page 130: ... Wheelbase 50 75 in 128 9 cm Ground Clearance 11 in 27 9 cm Dry Weight 740 lbs 336 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 EH68ALOE11 Displacement 683 Bore x Stroke 80 x 68 Pilot Jet 47 5 Main Jet 155 Needle Jet P 6 829 Jet Needle J8 4FA01 Pilot Screw 1 0 Alternator Output 330 Watts 3000 rpm Compression Ratio 9 78 1 Starti...

Page 131: ...0 2 Single Beam on Grill 27 Taillights watts 8 26 Brake Light watts 26 9 Instrument Cluster LCD Jetting and Clutching Charts Sportsman 700 Altitude AMBIENT TEMPERATURE Below 40 F Below 5 C 40 F and above 5 C and above Meters Feet 0 1800 0 6000 160 155 1800 3700 6000 12000 147 5 142 5 Altitude Shift Weight Drive Clutch Spring Driven Clutch Spring Helix Meters Feet 0 1800 0 6000 20 56 PN 5631315 Blu...

Page 132: ...egistration 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 COMPLETE AN ATV SAFETY TRAINING COURSE PROVIDED BY THE DEALER IN ORDER TO HAVE VALID WARRANTY ON THE ATV No verification of registration will be sent to the purchaser as the copy of the Warranty Registratio...

Page 133: ...rrosion 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 that are not compatible with the ATV The exclusive remedy for breach of this warranty shall be at Polaris exclusive option repair or replacement of any defective materials or components or products THE ...

Page 134: ...Registration 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 Servicing Dealer to perform warranty service Please work with your dealer to resolve any warranty issues Should your dealer require any additional assistance they will contact the appropriate person at Po...

Page 135: ...eling 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 Country where your vehicle was purchased If you are traveling temporarily outside the country where your vehicle was purchased you should take your vehicle to an authorized Polaris dealer You must show...

Page 136: ...ed 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 Vehicles registered to Government officials or mili tary personnel on assignment outside of the country where the vehicle was purchased will continue to be covered by the basic warranty For questions c...

Page 137: ...stic Mode 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 Switches 36 EMISSION CONTROL SYSTEMS 68 Engaging Front Gearcase 44 Engine Cooling System 89 Engine Stop Switch 36 Exhaust Emission Control System 68 Equipment Modifications 15 F FEATURES 44 49 Filter Systems 96 Front Gearca...

Page 138: ...ls and Locations 6 9 Safety Training 11 Setting the Parking Brake 40 Side Panel Removal 93 S Sidehilling 61 Spark Arrestor 103 Spark Plug Replacement 101 Spark Plugs 101 SPECIFICATIONS 122 129 Starting a Cold Engine 53 Starting a Warm Engine 54 Starting the Engine 53 54 Steering Assembly 92 Storage 110 113 Storage Tips 111 113 T TABLE OF CONTENTS 5 Tachometer 47 Taillight Brakelight Lamp Replaceme...

Page 139: ... ALCOHOL 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 before or while operating this vehicle Carry Passengers ALWAYS Avoid paved surfaces which may adversely affect handling and control Use proper RIDING TECHNIQUES to avoid vehicle overturns on hill...

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Summary of Contents for Sportsman 700 HO 2004

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Polaris Sportsman 700 HO 2004, Owner'S Manual, Page: 137 / 139

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Summary of Contents for Sportsman 700 HO 2004

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