Polaris Sprotsman 700 Safety And Maintenance Manual Download Page 147

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145

INDEX

Rider Information Center

57-61

. . . . . .

RIDING

70-81

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

Riding on Slippery Surfaces

. . . . . .

Riding Position

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

Safe Riding Gear

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

Safe Riding Tips

71-81

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

SAFETY

9-16

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

Safety Decals and Locations

14-21

. . . .

Safety Training

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

Safety Decals

15-43

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

Side Panel Removal

130

. . . . . . . . . . .

Sidehilling

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

Spark Arrestor

69, 122-123

. . . . . . . . . .

Spark Plug

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

Spark Plugs

120

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

Starting a Cold Engine

. . . . . . . . . .

Starting the Engine

64-65

. . . . . . . . . . .

Steering Inspection

104

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

Storage

131-132

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

Storage Tips

132

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

Switches

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

TABLE OF CONTENTS

4-5

. . . . . . . .

Taillight/Brakelight

Lamp Replacement

119

. . . . . . . .

Throttle Cable

Free Play Adjustment

110

. . . . . .

Throttle Lever

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

Tire Inspection

113

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

Tire Size

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

Toe Alignment

104-105

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

Tool Kit

134

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

Towing Capacity

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

Trail Obstacles

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

Transmission Lubrication

. . . . . . . .

Transmission Oil Change

. . . . . . . .

Transporting

134

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

Traveling Downhill

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

Traveling Uphill

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

Trip Meter

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

TROUBLESHOOTING

135-138

. . . . .

Turning Around on a Hill

. . . . . . . .

Turning Radius

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

Specifications

7-8

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

Understanding Warnings

. . . . . . . . . .

VEHICLE ID NUMBERS

. . . . . . . .

Warning, Read Owner’s Manual

. . . .

WARRANTY

141-143

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

Water Immersion

121

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

WELCOME

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

Wheel Removal

111

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

Wheel Installation

112

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

Wheel Nut Installation

112

. . . . . . . . .

Wheel Nut Torque Specifications

112

WIRING DIAGRAM

140

. . . . . . . . . .

Summary of Contents for Sprotsman 700

Page 1: ......

Page 2: ...WARNING The engine exhaust from this product contains chemicals known to cause cancer birth de fects or other reproductive harm...

Page 3: ...created a web site just for YOU Technical tips New product introductions Event schedules Parts and Service Manual information Exciting details about The Way Out Check it out www polarisindustries com...

Page 4: ...for safe and enjoyable operation of your vehicle Your Owner s Manual contains instructions for minor maintenance Major repairs are covered in the Polaris Service Manual and should be performed by a Fa...

Page 5: ...ing procedures You should review this information on a regular basis If you purchased a used Polaris ATV from a party other than a Polaris dealer you can request this free safety training from any aut...

Page 6: ...gs 9 Key Safety Issues 10 Decals and Locations 14 Operator Safety 23 Features and Controls 44 Controls 44 Features 54 Operation 62 Pre Ride Inspection 62 Vehicle Break In Period 63 Starting the Engine...

Page 7: ...Recommendations 88 Maintenance Record 92 Cooling System 93 Lubrication 96 Filter Systems 102 Adjustments 104 Lights 115 Spark Plugs 120 Water Immersion 121 Spark Arrestor 122 PVT 124 Battery 127 Side...

Page 8: ...rts If your vehicle is stolen these numbers are essential to its recovery and identification NOTE Record your vehicle s ID numbers in the spaces provided Remove the spare key and store it in a safe pl...

Page 9: ...ius 71 5 Engine Oil Capacity 2 Quarts Coolant Capacity 3 2 Quarts Engine EH68ALOE1 Displacement 683 Bore x Stroke 80 x 68 Pilot Jet 45 Main Jet 155 Needle Jet P 6 829 Jet Needle 4HB41 4 Pilot Screw 1...

Page 10: ...Handlebar 50 2 Single Beam on Grill 27 Taillights watts 8 26 Brake Light watts 26 9 Instrument Cluster LCD Clutching and Jetting Charts Altitude AMBIENT TEMPERATURE Below 40 F Below 5 C 40 Fand above...

Page 11: ...on 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 cau...

Page 12: ...available at the time of printing Polaris Industries Inc reserves the right to make product changes and improvements which may affect illustrations or explanations No part of this manual shall be rep...

Page 13: ...d also wear eye protection goggles or face shield gloves boots long sleeved shirt or jacket and long pants Never consume alcohol or drugs before or while operating this ATV Never operate at excessive...

Page 14: ...this manual on level ground Avoid crossing the side of a steep hill if possible Always use proper procedures if you stall or roll backwards when climbing a hill To avoid stalling maintain a steady sp...

Page 15: ...rs not have installed on a Polaris ATV any equipment which is intended to increase the speed or power of the vehicle or make any other modifications to the vehicle for these purposes Any modifications...

Page 16: ...your protection Read and follow the instructions on each decal carefully In the event any decal becomes illegible or comes off contact your Polaris dealer for a replacement Any safety decal needing r...

Page 17: ...15 SAFETY Safety Decals and Locations 1 7079083 1997 2000 IF OWNER S MANUAL IS MISSING CONTACT YOUR POLARIS DEALER FOR A REPLACEMENT WARNING...

Page 18: ...16 SAFETY Safety Decals and Locations 2 3...

Page 19: ...prevent flipover avoid sudden braking or sharp turns Use OVERRIDE for reverse speed limiter with caution To prevent loss of control never activate override button with open throttle PARKING BRAKE may...

Page 20: ...18 SAFETY Safety Decals and Locations 4 5 6...

Page 21: ...stance for braking when car rying cargo Overloading or carrying tall off center or unse cured loads will increase your risk of losing control Loads should be centered carried as low as possible and fi...

Page 22: ...TTENTION Operation of this vehicle without the air filter element will severely damage the engine Clean pre filter element often more frequent cleaning required in dusty conditions Do not operate vehi...

Page 23: ...dden 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 9 DO NOT TOW FROM RACK OR BUMPER Vehicle...

Page 24: ...tional Standards Institute 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 helmet face shield offer...

Page 25: ...rse and the 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 Fail...

Page 26: ...reduces your ability to balance and control this ATV Could cause an accident resulting in harm to you and or your passenger HOW TO AVOID THE HAZARD Never carry a passenger The long seat is to allow t...

Page 27: ...AN HAPPEN The ATV tires are designed for off road use Paved surfaces may seriously affect handling and control of the ATV and may cause the vehicle to go out of control HOW TO AVOID THE HAZARD Avoid o...

Page 28: ...eets roads or highways WHAT CAN HAPPEN You can collide with another vehicle HOW TO AVOID THE HAZARD Never operate this ATV on any public street road or highway even a dirt or gravel one In many states...

Page 29: ...r chances of a severe head injury or death in the event of an accident Operating without eye protection can result in an accident and increases your chances of a severe injury in the event of an accid...

Page 30: ...Could result in an accident HOW TO AVOID THE HAZARD Never consume alcohol or drugs before or while driving this ATV POTENTIAL HAZARD Operating this ATV at excessive speeds WHAT CAN HAPPEN Increases y...

Page 31: ...NTIAL HAZARD Attempting wheelies jumps and other stunts WHAT CAN HAPPEN Increases the chance of an accident including an overturn HOW TO AVOID THE HAZARD Never attempt stunts such as wheelies or jumps...

Page 32: ...ures and schedules described in the Owner s Manual POTENTIAL HAZARD Removing hands from handlebars or feet from footrests during operation WHAT CAN HAPPEN Removing even one hand or foot can reduce you...

Page 33: ...T CAN HAPPEN You can come upon hidden rocks bumps or holes without enough time to react Could result in the ATV overturning or going out of control HOW TO AVOID THE HAZARD Go slowly and be extra caref...

Page 34: ...Could cause loss of traction or vehicle control which could result in an accident including an overturn HOW TO AVOID THE HAZARD Do not operate on excessively rough slippery or loose terrain until you...

Page 35: ...t low speeds before attempting to turn at faster speeds Do not turn at excessive speed POTENTIAL HAZARD Operating on excessively steep hills WHAT CAN HAPPEN The vehicle can overturn more easily on ext...

Page 36: ...ribed in the Owner s Manual See pages 74 through 77 Always check the terrain carefully before you start up any hill Never climb hills with excessively slippery or loose surfaces Shift your weight forw...

Page 37: ...oing down hills as described in the Owner s Manual See page 76 NOTE A special technique is required when braking as you go downhill Always check the terrain carefully before you start down any hill Sh...

Page 38: ...any hill until you have mastered the turning technique as described in the Owner s Manual on level ground See page 77 Be very careful when turning on any hill Avoid crossing the side of a steep hill i...

Page 39: ...hill Apply the brakes Lock parking brake after you are stopped If you begin rolling backwards Keep weight uphill never apply engine power Never apply the rear brake while rolling backwards Apply the s...

Page 40: ...arge obstacles such as large rocks or fallen trees If you cannot avoid obstacles always follow proper procedures as described in the Owner s Manual POTENTIAL HAZARD Skidding or sliding WHAT CAN HAPPEN...

Page 41: ...voiding sudden movements maintain a slow and steady forward motion do not make sudden turns or stops and do not make sudden throttle changes Remember that wet brakes may have reduced stopping ability...

Page 42: ...L HAZARD Operating this ATV with improper modifications WHAT CAN HAPPEN Improper installation of accessories or modification of this vehicle may cause changes in handling which in some situations coul...

Page 43: ...ling a trailer Allow greater distance for braking Always follow the instructions in the Owner s Manual for carrying cargo or pulling a trailer See pages 66 through 68 POTENTIAL HAZARD Riding on frozen...

Page 44: ...arge obstacles such as large rocks or fallen trees If you cannot avoid obstacles always follow proper procedures as described in the Owner s Manual POTENTIAL HAZARD Skidding or sliding WHAT CAN HAPPEN...

Page 45: ...for possible damage 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...

Page 46: ...he center run position and turn the main key switch clockwise past the on position Release the key when the engine starts 3 Engine Stop Switch The engine will not start or run when the switch is in it...

Page 47: ...s will cease when the operator releases the throttle lever Choke Refer to the engine starting procedure on page 64 for correct choke and throttle settings during starting Do not start or operate an AT...

Page 48: ...t brake lever travel and reservoir fluid level before riding When squeezed the lever should feel firm Any sponginess would indicate a possible fluid leak or low master cylinder fluid level which must...

Page 49: ...straight If the fluid level is low add DOT 3 PN 2870990 only The Electronic Throttle Control ETC stops the engine in the event of a throttle system malfunction and is provided for your safety Do not...

Page 50: ...osition Important Safeguards The parking brake may relax when left on for a long period of time This could cause an accident Do not leave the vehicle on a hill depending on the parking brake for more...

Page 51: ...brake pedal pressure to brake the rear wheels without skidding Aggressively applying the rear brake when backing down a hill may cause rear tip over Brake Fluid Level It will be necessary to check th...

Page 52: ...cle storage and whenever transporting ON For normal operation RES For reserve supply in the event of main supply exhaustion NOTE There is about a 7 to 10 mile 11 2 to 16 km range on reserve gas Always...

Page 53: ...here gasoline is stored Do not over fill the tank Do not fill the tank neck If you get gasoline on your skin or clothing immediately wash it off with soap and water and change clothing Never start the...

Page 54: ...ons and in situations where you are operating below 7 miles per hour for extended periods of time Always place the transmission in park with the parking brake locked whenever the vehicle is left unatt...

Page 55: ...switch it will be located on the LH side of the engine next to the oil filler tube It is not to be confused with the engine temperature switch that is located on the same side but higher up on the eng...

Page 56: ...front wheels will automatically disengage NOTE The override switch also allows activation of All Wheel Drive AWD in reverse if All Wheel Drive switch is on There is no limit to the length of time the...

Page 57: ...When backing or while in All Wheel Drive and then going forward again the AWD hub may remain engaged If the hub remains engaged it can be disengaged by stopping shifting to and moving in reverse Then...

Page 58: ...mph Refer to page 44 for additional information 1 Rider Information Center 2 Speedometer needle in addition to depicting vehicle speed this needle will flash indicating a fault condition 3 Speedometer...

Page 59: ...is in H High Range L Low Range N Neutral R Reverse P Park E or blank Error Most of the time this error message will indicate you are inbetween gears It can however also indicate the transmission switc...

Page 60: ...ram the rider information center or to toggle through the options the machine cannot be in reverse Mode 1 Odometer This will record the amount of miles the ATV travels Mode 2 Trip Meter To reset the t...

Page 61: ...g 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...

Page 62: ...ed looks similar to this illustration and is referring to the software version currently installed in your machine This information is only briefly displayed Use the mode reverse override button to to...

Page 63: ...s needs adjustment please contact your dealer As long as you are in the diagnostic mode the wrench icon will remain lit To leave the diagnostic mode either shift the machine out of neutral or turn the...

Page 64: ...ches 6 Engine 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...

Page 65: ...ct an area which is open and will give you room to familiarize yourself with vehicle operation and handling 4 Vary the throttle positions Do not operate at sustained idle or sustained high speed 5 Per...

Page 66: ...le choke and can be adjusted gradually depending on how much choke is needed for starting 7 Do not press the throttle while starting the engine 8 Activate the starter for a maximum of five seconds rel...

Page 67: ...f you use your ATV all year round it is important to check your oil level frequently A rising oil level could indicate the accumulation of water in the bottom of the oil tank Water in the bottom of th...

Page 68: ...ground only with a maximum vertical hitch weight of 150 lbs 68 04 kg NOTE The rear rack capacity and tongue weight should not exceed 180 lbs Maximum grade while trailer towing 15 Do not tow any traile...

Page 69: ...ver HEAVY LOADS CAN CAUSE BRAKING AND CONTROL PROBLEMS Use extreme caution when applying brakes with a loaded vehicle Avoid terrain or situations which may require backing downhill ALL LOADS MUST BE S...

Page 70: ...urely fasten load and operate with ex tra caution Always attach the tow load to the hitch point designated for your ATV EXTREME CAUTION MUST BE USED when operating with loads extending over the rack s...

Page 71: ...D BELOW INCLUDE BUT ARE NOT LIMITED TO THE FOLLOWING 1 Removal or alteration or the puncturing of the muffler or any engine component which conducts removal of engine exhaust gases 2 Removal or altera...

Page 72: ...es 6 Engine 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...

Page 73: ...ing it to warm up 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 74: ...eer in the direction of the turn leaning your upper body to the inside of the turn while supporting your weight on the outer footrest The same leaning technique should be used for turning in reverse A...

Page 75: ...skid and shifting your body weight forward 4 Driving with All Wheel Drive All Wheel Drive engaged can assist in controlling the vehicle in slippery areas 5 Never apply brakes during a skid Complete l...

Page 76: ...weight forward 4 Proceed at a steady rate of speed and throttle opening 5 Remain alert and be prepared to take emergency action This may include quick dismounting of the ATV 25 Maximum Exercise extrem...

Page 77: ...he hill transferring your upper body weight toward the hill while keeping your feet on the footrests 3 Steer slightly into the hill to maintain vehicle directions If vehicle begins to tip quickly turn...

Page 78: ...o the rear of the vehicle 3 Slow down 4 Apply the brakes slightly to aid in slowing Familiarize yourself with the foot brake and its use in the event loss of normal service brakes occurs Do not travel...

Page 79: ...dlebars full left while facing front of ATV 5 While holding service brake release parking brake lock and slowly allow ATV to roll around to your right until ATV is pointing across the hill or slightly...

Page 80: ...water which exceeds the recommended maxi mum depth go slowly balance your weight carefully avoid sud den movements maintain a slow and steady forward motion Do not make sudden turns or stops and do n...

Page 81: ...you ride Stay on the right side of the trail if possible and be constantly alert for hazards such as logs rocks and low hanging branches Not all obstacles are visible Travel with caution on trails se...

Page 82: ...rride button while throttle is open Loss of control may result NOTE Most Polaris ATVs are equipped with a reverse speed limiter The override button should be used with caution as rearward vehicle spee...

Page 83: ...he Vehicle is Parked 1 Turn the engine off 2 Place the transmission in park 3 Set the parking brake 4 Avoid parking on an incline If it is necessary to park on an incline always block the rear wheels...

Page 84: ...fied dealer perform these operations Inspect clean lubricate adjust or replace parts as necessary NOTE Inspection may reveal the need for replacement parts Always use genuine Polaris parts available f...

Page 85: ...e Pre ride Replace engine coolant every two years Fuel and oil tanks Pre ride Pre ride Fill to proper levels Throttle Pre ride Pre ride Check operation Lights Pre ride Pre ride Check operation Engine...

Page 86: ...s Monthly Check Terminals clean check fluid level Engine breather filter 4 cycle 20 hrs Monthly Inspect replace annually and as needed Brake pad wear 20 hrs Monthly Inspect periodically Front and Rear...

Page 87: ...lace if necessary pre ride inspection item Choke Enricher Cable 50 hrs 6 months Inspect lubricate replace if necessary Coolant strength pressure test system 100 hrs 6 months Inspect strength seasonal...

Page 88: ...00 hrs 12 months Inspect and adjust as needed Fuel System 100 hours 12 months Check for leaks at tank cap lines fuel valve filter pump and carburetor Re place lines every two years Fuel Filter 100 hrs...

Page 89: ...100 hrs 12 months Inspect Adjust Brake fluid 200 hrs 24 months Change every two years Front wheel bearings 300 hrs 36 months Inspect replace if neces sary Idle Speed As Re quired As Re quired Adjust T...

Page 90: ...ge every two years or 200 hours 3 Transmis sion Oil Polaris Premium Synthetic gear case lube See Page 98 Change annually or at 100 hours 4 Front Gearcase Oil Premium Hub Lube See Page 99 Change annual...

Page 91: ...89 MAINTENANCE AND LUBRICATION Lubrication Recommendations 6 Front Prop Shaft U Joints 4 Front Gear Case 3 Transmission plug 7 Propshaft Yoke Fill plug Fill plug 5 Rear Gear Case...

Page 92: ...ate fittings and grease Semi annually 13 Lower Control Arms Grease Locate fittings and grease Semi annually 14 Rear Wheel Hub Bearing Carri er Grease Locate fitting and grease Semi annually 15 Rear An...

Page 93: ...Lubrication Recommendations 8 Axle Cardan Front Drive 11 Steering Post Bushing Upper 12 Upper Control Arm 14 Rear Wheel Hub Bearing Carrier 15 Rear Anti Roll Bar 13 Lower Control Arm 13 Lower Con trol...

Page 94: ...UBRICATION Periodic Maintenance Record Use the following chart to record periodic maintenance work Maintenance Interval Performed Servicing Date Servicing Dealer or Person Remarks First 5 Hrs 25 Hrs 5...

Page 95: ...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...

Page 96: ...level in the radiator should be inspected and coolant added if necessary To access the radiator pressure cap Using the tool provided remove the four screws securing front rack 1 Remove front cover 2...

Page 97: ...em be completely drained every two years and a fresh mixture of antifreeze and water be added Polaris recommends the use of Polaris Premium 60 40 anti freeze coolant or a 50 50 mixture of high quality...

Page 98: ...n ambient temperatures from 40 F to 120 F Its exceptional frictional properties result in more efficient operation more power output lower fuel consumption and easier starting in cold temperatures Alt...

Page 99: ...ckwise to remove 9 Using a clean dry cloth clean filter sealing surface on crankcase 10 Lubricate O ring on new filter with a film of new engine oil Check to make sure the O ring is in good condition...

Page 100: ...vel The correct transmission lubricant to use is Polaris Premium Synthetic Gearcase Lubricant PN 2871478 Model Oil Level A Oil Fill Ounces ml Sportsman 700 1 5 8 13 5 400 Transmission Oil Changing Pro...

Page 101: ...el surface remove fill plug and check the lubricant level Lubricant should be kept 3 4 from the bottom of the fill plug thread The correct gearcase lubricant to use is Premium Hub Lube Gearcase Oil Ch...

Page 102: ...GL5 80 90 weight gear lube Gearcase Oil Changing Procedure 1 Remove drain plug 2 Catch and discard used oil properly 2 Clean and reinstall the drain plug with a new sealing washer and tighten securely...

Page 103: ...e dipstick Remove the dipstick and wipe it clean 4 Re install the dipstick completely remove it and read the oil level NOTE Make certain the dipstick is inserted all the way into the filler tube to ke...

Page 104: ...ure of 40 PSI Always use a dispersion type nozzle to prevent filter damage and clean from the inside to the outside NOTE Replace the air filter every 50 hours and possibly more often in very dirty con...

Page 105: ...the filter 1 out of the hoses 2 Inspect filter for debris Blow through gently in direction of arrow on filter to check for clogging Replace as needed 3 Check hoses for cracks deterioration abrasion o...

Page 106: ...e Alignment You can check the toe alignment of the vehicle using the following method The recommended toe alignment is 1 8 to 1 4 3 to 6 cm toe out If you discover improper adjustment have your dealer...

Page 107: ...the stands making sure string just touches side surface of the rear tires on each side of machine and goes around the stands in front of the machine 4 Measure from string to rim at front and rear of f...

Page 108: ...ar Spring Adjustment The rear shock absorber spring is adjusted by rotating the adjuster in the direction required to increase or decrease spring tension NOTE Accessory springs are available through y...

Page 109: ...tank or any other part of machine when turned fully to left or right 4 Torque handlebar adjuster block bolts to 10 to 12 ft lbs NOTE Tighten bolts so there is an equal gap at the front and rear of the...

Page 110: ...ndicated and the diaphragm should be replaced Always fill the reservoir as indicated whenev er the cover is loosened or removed to insure proper diaphragm operation Use Polaris DOT 3 brake fluid Check...

Page 111: ...l is worn to 3 64 1 cm which is about the thickness of a dime Inspect the brake disc spline and pad wear surface for excessive wear Foot Brake Your ATV s foot brake is intended to be used as a backup...

Page 112: ...r out until the desired idle RPM is reached Turning the screw in clockwise will raise RPM Turning the screw out counterclockwise will lower RPM Throttle Cable Free Play Adjustment Throttle cable free...

Page 113: ...ehicle handling and tire wear Wheel Removal Procedure 1 Stop the engine place the transmission in park and lock the parking brake 2 Loosen the wheel nuts slightly 3 Elevate the side of the vehicle by...

Page 114: ...allation The wheel nuts on your ATV have been installed with thread locker as an extra measure to ensure retention This feature is intended to last until the wheel nuts are removed NOTE Wheel nut remo...

Page 115: ...INTENANCE AND LUBRICATION Adjustments Tire Inspection When replacing a tire always use original equipment size and type Tire Tread Depth Always replace tires when tread depth is worn to 1 8 3 cm 1 or...

Page 116: ...efficient operation These changes include 1 Carburetor re jetting to compensate for altitude and or temperature changes 2 Transmission convertor modification to adjust for engine horsepower loss durin...

Page 117: ...llights clean Poor lighting while riding can result in an accident causing severe injury or death Do not service while headlight is hot Serious burns may result Do not touch a halogen lamp with bare f...

Page 118: ...t pod cover up Disconnect instrument cluster harnesses from instrument cluster Unplug indicator light harness and remove pod cover 5 Unplug headlamp from wiring harness 6 Remove boot and locking colla...

Page 119: ...h the headlight approximately 25 7 6 m from a wall 2 Measure the distance from the floor to the center of the headlight and make a mark on the wall at the same height 3 Start the engine and turn the h...

Page 120: ...t instrument cluster harnesses from instrument cluster Unplug indicator light harness and remove pod cover 5 Unplug headlamp from wiring harness 6 Remove O Ring from headlight pivot pins 7 Pull headli...

Page 121: ...es not work the lamp may need to be replaced 1 Remove the taillight lens cover mounting screws Remove the lense cover and gasket and set aside for reassembly 2 Remove lamp A and replace it with recomm...

Page 122: ...heating caused by use of an improper spark plug or incorrect carburetion adjustments 2 Wet Fouled The insulator tip is black A damp oil film covers the firing end There may be a carbon layer over the...

Page 123: ...Dry the spark plugs and reinstall or replace with a new plugs Tighten the carburetor drain screw Turn the fuel valve on Attempt to start the engine If neces sary repeat the drying procedure Take the...

Page 124: ...es When cleaning the spark arrestor you must follow the safeguards listed below to avoid serious injury or death Do not perform this operation immediately after the engine has been run because the exh...

Page 125: ...is in neutral and repeat steps 2 and 3 5 If particles are still suspected to be in the muffler drive the machine onto the incline so the front of the machine is one foot higher than the rear Set the...

Page 126: ...tensive engineering and testing has been conducted to insure the safety of this product However as the owner you have the following responsibilities to make sure this system remains safe Do not modify...

Page 127: ...overs to fail By switching to low range while operating at low ground speeds the air temperature in the clutch cover is reduced by almost 160 degrees Reducing the temperature inside the clutch cover e...

Page 128: ...owing lists provide a guideline for when to use low range rather than high Low Range Basic operation at speeds less than 7 MPH Heavy pulling Riding through rough terrain swamps mountains etc at low gr...

Page 129: ...situation could result causing serious injury or death WARNING Battery electrolyte is poisonous It contains sulfuric acid Serious burns can result from contact with skin eyes or clothing Antidote Exte...

Page 130: ...essary remove the corrosion with a stiff wire brush Wash with a solution of one tablespoon baking soda and one cup water Rinse well with tap water and dry off with clean rags Coat the terminals with d...

Page 131: ...negative cable 5 Reinstall battery and battery strap 6 Verify that cables are properly routed NOTE When your ATV is placed in storage for three months or more the battery should be removed charged to...

Page 132: ...e panel forward and outward to disengage the two rear tabs 2 Place hand on top of side panel behind the fuel tank With a quick and firm motion push down on the side panel to disengage the top rear two...

Page 133: ...gs immediately after washing Also run the vehicle to evaporate any water that might have entered the engine or exhaust system The best and safest way to clean your ATV is with a garden hose and a pail...

Page 134: ...for the stabilizer to disperse through the fuel in the tank and carburetor Turn the fuel valve to OFF and drain the carburetor bowl completely Oil And Filter Change 4 Strokes Warm the engine and chan...

Page 135: ...s 1 265 or greater Store the battery in a cool dry place Charge can be maintained easily by using Polaris Battery Tender charger PN 2871076 or by charging about once a month to make up for normal self...

Page 136: ...e frame of the ATV to the transporting unit securely using suitable straps or rope 5 Always place the transmission in park and lock the parking brake Tool Kit To help you perform routine maintenance a...

Page 137: ...of Low Range is high ly recommended for cooler PVT oper ating temperatures and longer compo nent life Insufficient warm up of ATVs exposed to low ambi ent temperatures Warm engine at least 5 min then...

Page 138: ...veral times as required During this proce dure the throttle should not be held at the full position for more than 5 sec onds Clutch compartment seals should be inspected for damage if re peated leakin...

Page 139: ...ns you may have about the operation of your ATV See your Polaris dealer with any additional questions you may have ENGINE TURNS OVER BUT FAILS TO START No Fuel Water in Fuel Spark Plug Fuel Valve Off...

Page 140: ...r Dealer Overuse of Choke Spark Plug Fouled Engine Overheated Clean Engine Exterior Turn Fuel Valve to Res Water in Fuel Air Filter Clogged Reverse Speed Limiter Malfunction Electronic Throttle Contro...

Page 141: ...139 NOTES...

Page 142: ...140 WIRING DIAGRAM...

Page 143: ...the time of sale the Warranty Registration 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 wa...

Page 144: ...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 145: ...ce you must present your copy of the Warranty Registration form to the dealer THE COST OF TRANSPORTATION TO AND FROM THE DEALER IS YOUR RESPONSIBILITY Polaris suggests that you use your original selli...

Page 146: ...4 Features 54 61 Filter Systems 102 103 Fogging The Engine 133 Front Gearcase Lubrication 99 Fuel Capacity 7 Fuel Filter 50 Fuel Safety 51 Fuel Stabilizer 132 Fuel System 50 fuel valve 50 Gear Reducti...

Page 147: ...Taillight Brakelight Lamp Replacement 119 Throttle Cable Free Play Adjustment 110 Throttle Lever 45 Tire Inspection 113 Tire Size 8 Toe Alignment 104 105 Tool Kit 134 Towing Capacity 7 Trail Obstacle...

Page 148: ......

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