Polaris Sportsman 2004 Owner's Manual

Pant
one
644
WARNING
Improper vehicle use can result in SEVERE INJURY or DEATH.
ALWAYS USE
HELMET AND PROTECTIVE
GEAR
NEVER USE
ON PUBLIC
ROADS
NEVER:
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.
NEVER CARRY
PASSENGERS
NEVER USE
WITH DRUGS
OR ALCOHOL
ALWAYS:
Avoid paved surfaces, which may adversely affect handling and control. Use proper RIDING TECHNIQUES to avoid vehicle overturns on hills
and rough terrain, and in turns. Wear eye protection, helmet and protective apparel.
READ OWNER'S MANUAL.
FOLLOW ALL INSTRUCTIONS AND WARNINGS.
Part No. 9918724 Rev 06 PRINTED IN THE USA
WARNING
The engine exhaust from this
product contains chemicals known
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.
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2
Copyright 2003 Polaris Sales Inc. All information contained within this publication is based on the latest product information at the time of publication. Due to constant improvements in the design and quality of production components, some minor discrepancies may result between the actual vehicle and the information presented in this publication. Depictions and/or procedures in this publication are intended for reference use only. No liability can be accepted for omissions or inaccuracies. Any reprinting or reuse of the depictions and/or procedures contained within, whether whole or in part, is expressly prohibited. Printed in U.S.A.
3
WELCOME
Thank you for purchasing a Polaris vehicle, and welcome to our world-wide family of P olaris owners. We proudly produce an exciting line of utility and recreational products.
Polaris Recreational Vehicles
S Snowmobiles S All-terrain vehicles (ATVs) S Watercraft S RANGER utility vehicles S Victory motorcycles
Polaris Professional Series Workmobilest
S Utility Task Vehiclest (UTVs) S Personal Task Vehiclest (PTVs) S All-Surface Loaders (ASLs)
We believe Polaris sets a standard of excellence for all utility and recreational vehicles manufactured in the world today. Many years of experience have gone into the engineering, design, and development of your Polaris vehicle, making 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 S ervice Manual and should be performed only by a Factory Certified Master Service Dealer (MSD) Technician.
Your Polaris dealer knows your vehicle best and is interested in your total satisfaction. Be sure to return to your dealership for all of your service needs during, and after, the warranty period.
We also take great pride in our P arts Apparel and Accessories (PAA) products, available through our online store at www.purepolaris.com. Have your accessories and clothing delivered right to your door!
Polaris, Polaris The Way Out, and Workmobiles are registered trademarks of Polaris Industries Inc.
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VEHICLE IDENTIFICATION NUMBERS
The frame vehicle identification number (VIN)(1) and engine serial number (2) are important for model i dentification when registering your vehicle, when obtaining insurance, and when ordering replacement parts. In the event your vehicle is stolen, 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
400/500
600/700
Frame VIN:
Engine Serial Number:
Vehicle Model Number:
Key Number:
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TABLE OF CONTENTS
WELCOME 3........................................
VEHICLE IDENTIFICATION NUMBERS 4...............
SAFETY 6..........................................
CONTROLS 36......................................
FEATURES 44.......................................
OPERATION 50.....................................
EMISSION CONTROL SYSTEMS 68...................
MAINTENANCE AND LUBRICATION 69................
ADJUSTMENTS 112.................................
POLARIS PRODUCTS 115............................
TROUBLESHOOTING 116............................
SPECIFICATIONS 120................................
W ARRANTY 128.....................................
INDEX 133..........................................
6
SAFETY
Safety Decals and Locations
Warning decals have been placed on the ATV for your protection. Read and follow the instructions of the decals on the ATV carefully. If any of the decals depicted in this manual differ from the decals on your ATV, always read and follow the instructions of the decals on the ATV.
If any decal becomes illegible or comes off, contact your Polaris dealer to purchase a replacement. Replacement safety decals are provided by Polaris at no charge. The part number is printed on the decal.
7079083
E1997, 2000
IF OWNER’S MANUAL IS MISSING, CONTACT
A POLARIS DEALER FOR A REPLACEMENT .
WARNING
Operating this vehicle if you are under the age of 16 increases your chance of severe injury or death.
NEVER operate this vehicle if you are under age 16.
WARNING
WARNING
7077920
WARNING
7
SAFETY
Safety Decals and Locations
IMPROPER TIRE PRESSURE OR OVERLOADING can cause loss of control resulting in SEVERE INJURY OR DEATH.
TIRE PRESSURE IN PSI (KPa): FRONT 5 (34,5) REAR 5 (34,5)
MAXIMUM WEIGHT CAPACITY (Gross Vehicle Weight) INCLUDING MACHINE, DRIVER A ND CARGO IS 1200 LBS. (545 kg).
Reduce speed and allow greater distance for braking when carrying cargo. Overloading or carrying tall, off-center, or unsecured loads will inc rease your risk of losi ng control. Loads should be centered, carried as low as possible, and firmly secured to the racks. With dual racks, load distribution 1/3 front 2/3 rear is best. For stability on rough or hilly terrain, reduce speed and cargo. Do not block headlight. Be c areful if load extends over the side of the rack.
Read Owner’s Manual for more detailed loading i nformation
WARNING
7079084
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 required in dusty conditions. Do not operate vehicle without pre-filter.
S Operation of this vehicle without engine
breather filter(s) can cause engine damage. Consult owner’s manual or dealer for details.
Factory setting:
40_ to 80_ F. at 0-3000 feet
(5_ to 27_ C. at 0-900 meters).
7079902
S Specific carburetor jetting and
adjustments are required depending on temperature and altitude. See your Owner’s Manual.
8
SAFETY
Safety Decals and Locations
Moving parts haz ard under belt-c l utc h guard. To prevent serious injury, do not operate vehicle with guard r emov ed.
Do not modify engine or clutch. Doing so can cause part failure, possible imbalance, and excessive engine RPM which can result in serious injury or death.
NO STEP
7078689
WARNING
S DO NOT TOW FROM RACK OR BUMPER.
Vehicle damage or tipover may res ult 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 res ult causing severe injury or death. Tow only from tow hooks or hitch.
S Max Rack Loads: Front 90 lbs. (41 kg) Rear 180 lbs. (82 kg)
7170021
WARNING
Sportsman 400/500
Sportsman 600/700
9
SAFETY
Safety Decals and Locations
ALL WHEEL
DRIVE
SWITCH
Do not push switch to engage AWD if the rear wheels are spinning. This may cause severe drive shaft and clutch damage. See your Owner’s Manual.
7079780
7079604
7170509
TRAILER MAX WEIGHT: 1500 LBS. (682 KG) ON LEVEL GROUND 850 LBS. (386 KG) UP TO 15° GRADE
HITCH MAX. VERTICAL WEIGHT: 150 LBS. (68KG)
WARNING
Pushing reverse override button may cause sudden in­creases in pow­er and traction if too much throttle is ap­plied. Loss of control or for­ward flipover may result, es­pecially in AWD. See Own­er’s Manual .
7170911
TRAILER MAX WEIGHT: 1225 LBS. (557 KG) ON LEVEL GROUND 850 LBS. (386 KG) UP TO 15° GRADE
HITCH MAX. VERTICAL WEIGHT: 120 LBS. (55KG)
Sportsman 600/700
Sportsman 400/500
MANUFACTURED BY: POLARIS IND. INC.
DATE:
VIN:
THIS VEHICLE IS AN ALL TERRAIN VEHICLE AND IS NOT INTENDED FOR USE ON PUBLIC ROADS.
7171492
CE VÉHICULE EST UN V É HICULE TOUT TERRAIN QUI NiEST PAS DEST I NÉ À ÊTRE UTILISÉ SUR LES CHEMINS PUBLICS.
Canadian Certification Decal
10
SAFETY
Safe Riding Gear
Always wear clothing suited to the type of riding. ATV riding requires special protective clothing for comfort and to reduce t he chance of injury.
1. Helmet
Your helmet is the most important piece of protective gear for safe riding. A helmet can prevent a severe head injury.
Select an approved helmet that meets or exceeds your state’s safety standards and bears either the Department of Transportation (DOT) label, the American National 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 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. Boots
The best footwear is a pair of strong over-the-calf boots with heels, like moto-cross boots.
5. Clothing
Always wear long sleeves and long pants to protect arms and legs. Riding pants with kneepads and a jersey with shoulder pads provide the best protection.
1
2
3
4
5
11
SAFETY
Operator Safety
Age Restrictions
This vehicle is an ADULT VEHICLE ONLY. Operation is prohibited for anyone under 16 years of age.
Know Your Vehicle
As the operator of the vehicle, you are responsible for your personal safety, the safety of others, and the protection of our environment. Read and understand your owner ’s manual, which includes valuable information about all aspects of your vehicle, including safe operating procedures.
Safety Training
When you purchased your new ATV, your dealer offered a hands-on safety training course that covers all aspects of vehicle safety. You were also provided with printed materials that explain safe operating 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 authorized Polaris dealer.
A Polaris ATV is an off-road vehicle. Familiarize yourself with all laws and regulations concerning the operation of the ATV 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 that all critical components on your vehicle are thoroughly inspected at specific intervals.
WARNING
Failure to follow the warnings contained in this manual can result in severe injury or death.
A Polaris ATV is not a toy and can be hazardous to operate. This vehicle handles differently than other vehicles, such as motorcycles and cars. A collision or rollover can occur quickly, even during routine maneuvers like turning, or driving on hills or over obstacles, if you fail to take proper precautions.
Read and understand your owner’s manual and all warnings before operating a Polaris ATV.
12
SAFETY
Operator Safety
The following two pages identify signal words and symbols that appear in this manual. Your safety is involved when these words and symbols are used. Become familiar with their meanings before reading the manual.
The safety alert symbol, 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 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 situation that may result in damage to the vehicle.
CAUTION
WARNING
13
SAFETY
Operator Safety
S Read this manual and all labels carefully, and follow the operating
procedures described.
S Never operate an ATV without proper instruction. Take a training
course. Beginners should receive training from a certified instructor.
Contact an authorized Polaris ATV dealer or call Polaris at 1-800-342-3764 to find out about the training courses nearest you.
S Never allow anyone under 16 years of age to operate this ATV. S Never permit a guest to operate the ATV unless the guest has read
this manual and all product labels and has completed a certified safe­ty training course.
S Always avoid operating an ATV on paved surfaces, including side-
walks, driveways, parking lots, and streets.
S Never operate an ATV on a public street, road or highway, including
a dirt or gravel road.
S Never operate an ATV without wearing an approved helmet that fits
properly. Always wear eye protection (goggles or face shield), gloves, boots, a l ong-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. Always follow the inspection and maintenance procedures and schedules outlined in your owner’s manual.
S Always keep both hands on the handlebars and both feet on the foot-
rests of the ATV during operation.
S Always travel slowly and use extra caution when operating on unfa-
miliar terrain. Be alert to changing terrain conditions.
S Never operate on excessively rough, slippery, or loose terrain. S Always follow proper turning procedures as described in this manu-
al. Practice turning at low speeds before attempting to turn at faster speeds. Do not turn at excessive speeds.
WARNING
Serious injury or death can result if you do not follow these instructions and procedures, which are outlined in further detail within your owner’s manual.
14
SAFETY
Operator Safety
S Always have the ATV inspected by an authorized Polaris dealer if
it’ s been involved in an accident.
S Never operate on hills too steep for the ATV or for your abilities.
Practice on smaller hills before attempting larger hills.
S Always follow proper procedures for climbing hills. Check the ter-
rain carefully before ascending a hill. Never climb hills with exces­sively slippery or loose surfaces. Shift your weight forward. Never open the throttle suddenly or make sudden gear changes. Never go over the top of a hill at high speed.
S Always follow proper procedures for going downhill and for braking
on hills. Check the terrain carefully before you start down a hill. Shift your weight backward. Never go down a hill at high speed. Avoid going down a hill at an angle, which would cause the vehicle to lean sharply to one side. Travel straight down the hill when pos­sible.
S Always follow proper procedures for crossing the side of a hill.
Avoid hills with excessively slippery or loose surfaces. Shift your weight to the uphill side of the ATV. Never attempt to t urn the ATV around on any hill until you’ve mastered (on level ground) the turn­ing 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 t he special procedure for braking described in this manual. Always dismount on the uphill side, or to either side if the ATV is pointed straight uphill. Turn the ATV around and remount following the procedure described in this manual.
S Always check for obstacles before operating in a new area. Never
attempt to operate over large obstacles, such as rocks or fallen trees. Always follow proper procedures when operating over obstacles as described in this manual.
S Always be careful of skidding or sliding. On slippery surfaces like
ice, travel slowly and use extra caution to reduce the chance of skid­ding or sliding out of control.
S Avoid operating the ATV through deep or fast-flowing water. If it’s
unavoidable, travel 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.
15
SAFETY
Operator Safety
S Wet brakes may have reduced stopping ability. Test the brakes after
leaving water. If necessary, apply them lightly several times to allow friction to dry out the pads.
S Always check for obstacles or people behind the ATV before operat-
ing in reverse. When it’ s safe to proceed in reverse, move slowly and avoid turning at sharp angles.
S Always use the size and type of tires specified for your ATV, and
always maintain proper tire pressure.
S Never modify an ATV through improper installation or use of acces-
sories.
S Never exceed the stated load capacity for your ATV. Cargo must be
properly distributed and securely attached. Reduce speed and follow the instructions in this manual for carrying cargo or towing. Allow a greater distance for braking.
FOR MORE INFORMATION ABOUT ATV SAFETY, call the Con­sumer 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 t he 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 these purposes. Any modifications to the original equipment of the vehicle create a substantial safety hazard and increase the risk of bodily injury.
The warranty on your Polaris ATV is terminated if any equipment has been added to the vehicle, or if any modifications have been made to the vehicle, that increase its speed or power .
NOTE: The addition of certain accessories, including (but not limited to) mowers, blades, tires, sprayers, or large racks, may change the handling characteristics of the vehicle. Use only Polaris-approved accessories, and familiarize yourself with their function and effect on the vehicle.
16
SAFETY
Operator Safety
POTENTIAL HAZARD
Operating this ATV without proper instruction.
WHAT CAN
HAPPEN
The risk of an accident is greatly increased if the operator does not know how to operate the ATV properly in different situations and on different types of terrain.
HOW TO AVOID THE
HAZARD
Beginning and inexperienced operators should complete the certified training course offered by Polaris. Operators should regularly practice the skills learned in the course 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
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 recommended age group for operating some ATVs, he/she may not have the skills, abilities, or judgment needed to operate an ATV safely and could be susceptible to accident or injury.
HOW TO AVOID THE
HAZARD
No one under the age of 16 should operate a Polaris ATV.
WARNING
WARNING
17
SAFETY
Operator Safety
POTENTIAL HAZARD
Carrying a passenger on an ATV.
WHAT CAN
HAPPEN
Carrying a passenger greatly reduces 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
18
SAFETY
Operator Safety
POTENTIAL HAZARD
Operating an ATV on paved surfaces, including sidewalks, paths, parking lots, and driveways.
WHAT CAN
HAPPEN
ATV tires are designed for off-road use. Operating on paved surfaces may adversely affect the handling of the A TV 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
19
SAFETY
Operator Safety
POTENTIAL HAZARD
Operating this ATV on public streets, 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
20
SAFETY
Operator Safety
POTENTIAL HAZARD
Operating this ATV without wearing an approved helmet, eye protection and protective clothing.
WHAT CAN
HAPPEN
Operating an ATV without an approved helmet increases 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.
WARNING
21
SAFETY
Operator Safety
POTENTIAL HAZARD
Operating the ATV after consuming alcohol or drugs.
WHAT CAN
HAPPEN
Consumption of alcohol and/or drugs could seriously affect operator judgment. Reaction time may be slower and operator balance and perception could be affected.
Consuming alcohol and/or drugs before or while operating 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 operate the ATV at a speed that’s proper for the terrain, visibility and operating conditions, and your experience.
WARNING
WARNING
22
SAFETY
Operator Safety
POTENTIAL HAZARD
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
23
SAFETY
Operator Safety
POTENTIAL HAZARD
Failure to inspect the ATV before operating.
Failure to properly maintain the ATV.
WHAT CAN
HAPPEN
Poor maintenance increases the possibility of an accident or equipment damage.
HOW TO AVOID THE
HAZARD
Always inspect your ATV before each use to make sure it’s in safe operating condition.
Always follow the inspection and maintenance procedures 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 wheels and lead to accident or injury.
HOW TO AVOID THE
HAZARD
Always keep both hands on the handlebars and both feet on the footrests of the A TV during operation.
WARNING
WARNING
24
SAFETY
Operator Safety
POTENTIAL HAZARD
Failure to use extra caution when operating the ATV 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
25
SAFETY
Operator Safety
POTENTIAL HAZARD
Failure to use extra caution when operating on excessively rough, slippery or loose terrain.
WHAT CAN
HAPPEN
Operating on excessively 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
26
SAFETY
Operator Safety
POTENTIAL HAZARD
Turning improperly.
WHAT CAN
HAPPEN
Improper turns could cause loss of control and lead to a collision or overturn.
HOW TO AVOID THE
HAZARD
Always follow proper procedures for turning as described 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 attempting large hills.
WARNING
WARNING
27
SAFETY
Operator Safety
POTENTIAL HAZARD
Climbing hills improperly.
WHAT CAN
HAPPEN
Improper hill climbing could cause loss of control or overturn.
HOW TO AVOID THE
HAZARD
Always follow proper procedures for climbing hills as described in the owner’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 could be on the other side of the hill.
WARNING
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