Polaris Sportsman S User Manual

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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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All information in this manual is based on the latest product data and specifications available at the time of printing. 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.

WELCOME

Thank you for purchasing a Polaris vehicle, and welcome to our world-wide family of Polaris 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, m aking it t he 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 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 Parts 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.

VEHICLE IDENTIFICATION NUMBERS

The frame vehicle identification number (VIN)(1) and engine serial number (2) are important for model identification 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.

Frame VIN:

Vehicle Model Number:

Engine Serial Number:

Key Number:

31XX

600/700

400/500

TABLE OF CONTENTS

WELCOME 3........................................

VEHICLE 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..........................................

SAFETY

Safety Decals and Locations

Warning decals have been placed on the ATV for your protection. Read and follow the instructions on each decal carefully. If a 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.

WARNING

IF OWNER’S MANUAL I S MISSING, CONTACT

A POLARIS DEALER FOR A REPLACEMENT.

E1997, 2000

7079083

WARNING

DNever operate this vehicle on HILLS steeper than 25 degrees

25°.To prevent flipover on hilly terrain, whengoing up or down,use

throttle and brakes gradually.

DREVERSE operation c an 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.

DPARKING BRAKE may relax when used for more than 5 minutes.

When parking on grades, leave shift in forward.

7079085

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.

Safety Decals and Locations

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.

S Specific carburetor jetting and

WARNING

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) REA R 5 (34,5)

MAXIMUM WEIGHT CAPACITY (Gross Vehicle Weight) INCLUDING MACHINE, DRIVER AND 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 increase your risk of losing 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 careful if load extends over the side of the rack.

Read Owner’s Manual for more detailed loading information

7079084

SAFETY

adjustments are required depending on temperature and altitude. See your Owner’s Manual.

Factory setting:

40_ to 80_ F. at 0-3000 feet

(5_ to 27_ C. at 0-900 meters).

7079902

WARNING

7077920

SAFETY

Safety Decals and Locations

WARNING

Moving parts hazard under belt-clutc h guard. To prevent s erious injury, do not operate vehic le with guard removed.

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

S DO NOT TOW FROM RACK OR BUMPER.

Vehicle damage or tipov er may res ult causing severe i njury or death. Tow only from tow hooks or hitch.

S Max Rack Loads: Front 90 lbs. (41 kg) Rear 180 lbs. (82 kg)

Sportsman 400/500

S DO NOT TOW FROM RACK OR BUMPER.

Vehicle damage or tipov er may res ult causing severe i njury or death. Tow only from tow hooks or hitch.

S Max Rack Loads: Front 100 lbs. (45 kg) Rear 200 lbs. (91 kg)

Sportsman 600/700

WARNING

7170021

WARNING

7170912

Safety Decals and Locations

SAFETY

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.

7079604

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

THIS VEHICL E IS AN ALL TERRAIN VEHICLE AND IS NOT INTENDED FOR USE ON PUBLIC ROADS.

CE VÉHICULE EST UN VÉHICULE TOUT TERRAIN QUI NEST PAS DESTINE A ETRE UTILISE SUR LES CHEMINS PUBLICS.

Canadian Certification Decal

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 400/500

MANUFACTURED BY: POLARIS IND INC.

DATE:

VIN:

7170911

7078470

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)

Sportsman 600/700

7170509

SAFETY

Safe Riding Gear

Always wear clothing suited to the type of riding. ATV riding requires special protective clothing for comfort and to reduce the 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.

SAFETY

Operator Safety

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.

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 i nformation on a regular basis.

If you purchased a used Polaris A TV 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 this vehicle in your area.

We strongly advise you to strictly follow the recommended maintenance program outlined in your owner’s manual. This preventive m aintenance program is designed to ensure that all critical components on your vehicle are thoroughly i nspected at specific intervals.

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.

WARNING

The safety alert warning indicates a potential hazard that may result in serious injury or death.

CAUTION

The safety alert caution indicates a potential hazard that may result in minor personal injury or damage to the vehicle.

CAUTION

A caution indicates a situation that may result in damage to the vehicle.

NOTE:

A note will alert you to important information or instructions.

SAFETY

Operator Safety

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.

S Read this manual and all labels carefully, and follow the operating

procedures described.

S Never operate an ATV without proper i nstruction. 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 l abels 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 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. 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 t urning 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.

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. C heck 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 turn the ATV around on any hill until you’ve mastered (on level ground) the t urning 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 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 s teady forward motion. Do not make sudden turns or stops, and do not make sudden throttle changes.

SAFETY

Operator Safety

S Wet brakes m ay 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 P roduct 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 A TV 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.

SAFETY

Operator Safety

WARNING

POTENTIAL HAZARD Operating this ATV without proper instruction. WHAT CAN 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 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.

HAPPEN

HAZARD

WARNING

POTENTIAL Failure to follow the age recommendations for this ATV. WHAT CAN 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 No one under the age of 16 should operate a Polaris ATV.

HAZARD

HAPPEN

HAZARD

Operator Safety

WARNING

POTENTIAL HAZARD Carrying a passenger on an ATV. WHAT CAN 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 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.

HAPPEN

HAZARD

SAFETY

Operator Safety

WARNING

POTENTIAL HAZARD Operating an ATV on paved surfaces, including sidewalks,

paths, parking lots, and driveways. WHAT CAN 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 Avoid operating the ATV on pavement. If it’s unavoidable,

travel slowly and avoid sudden turns or stops.

HAPPEN

HAZARD

Operator Safety

SAFETY

WARNING

POTENTIAL HAZARD Operating this ATV on public streets, roads or highways. WHAT CAN The ATV could collide with another vehicle. HOW TO AVOID THE 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.

HAPPEN

HAZARD

SAFETY

Operator Safety

WARNING

POTENTIAL HAZARD Operating this ATV without wearing an approved helmet, eye

protection and protective clothing. WHAT CAN 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 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.

HAPPEN

HAZARD

Operator Safety

WARNING

POTENTIAL HAZARD Operating the ATV after consuming alcohol or drugs. WHAT CAN 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 Never consume alcohol or drugs before or while operating an

ATV.

HAPPEN

HAZARD

WARNING

SAFETY

POTENTIAL Operating the ATV at excessive speeds. WHAT CAN 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 Always operate the ATV at a speed that’s proper for the terrain,

visibility and operating conditions, and your experience.

HAZARD

HAPPEN

HAZARD

SAFETY

Operator Safety

WARNING

POTENTIAL HAZARD Attempting wheelies, jumps and other stunts. WHAT CAN Attempting stunts increases the chance of an accident, including

an overturn. HOW TO AVOID THE Never attempt wheelies, jumps, or other stunts. Avoid exhibition

driving.

HAPPEN

HAZARD

Operator Safety

WARNING

POTENTIAL HAZARD Failure to inspect the ATV before operating. Failure to properly maintain the ATV. WHAT CAN Poor maintenance increases the possibility of an accident or

equipment damage. HOW TO AVOID THE 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.

HAPPEN

HAZARD

WARNING

SAFETY

POTENTIAL Removing hands from the handlebars or feet from the

footrests during operation. WHAT CAN 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 Always keep both hands on the handlebars and both feet

on the footrests of the ATV during operation.

HAZARD

HAPPEN

HAZARD

SAFETY

Operator Safety

WARNING

POTENTIAL HAZARD Failure to use extra caution when operating the ATV on unfamiliar

terrain. WHAT CAN Unfamiliar terrain may contain hidden rocks, bumps, or holes that

could cause loss of control or overturn. HOW TO AVOID THE Travel slowly and use extra caution when operating on unfamiliar

terrain. Always be alert to changing terrain conditions.

HAPPEN

HAZARD

Operator Safety

WARNING

POTENTIAL HAZARD Failure to use extra caution when operating on excessively

rough, slippery or loose terrain. WHAT CAN 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 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.

HAPPEN

HAZARD

SAFETY

Operator Safety

WARNING

POTENTIAL HAZARD Turning improperly. WHAT CAN Improper turns could cause loss of control and lead to a collision

or overturn. HOW TO AVOID THE 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.

HAPPEN

HAZARD

WARNING

POTENTIAL Operating on excessively steep hills. WHAT CAN The vehicle may overturn. HOW TO AVOID THE 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.

HAZARD

HAPPEN

HAZARD

SAFETY

Operator Safety

WARNING

POTENTIAL HAZARD Climbing hills improperly. WHAT CAN Improper hill climbing could cause loss of control or overturn. HOW TO AVOID THE 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.

HAPPEN

HAZARD

SAFETY

Operator Safety

WARNING

POTENTIAL HAZARD Traveling downhill improperly. WHAT CAN Improperly descending a hill could cause loss of control or

overturn. HOW TO AVOID THE Always follow proper procedures for 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 when possible.

HAPPEN

HAZARD

SAFETY

Operator Safety

WARNING

POTENTIAL HAZARD Improperly crossing hills and turning on hills. WHAT CAN Improperly crossing or turning as hills could cause loss of control

or overturn. HOW TO AVOID THE Never attempt to turn 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 Always follow proper procedures as described in the owner’s

manual. Avoid hills with excessively slippery or loose surfaces. Shift your weight to the uphill side of the ATV .

HAPPEN

HAZARD

hill:

SAFETY

Operator Safety

WARNING

POTENTIAL HAZARD Stalling, rolling backwards or

improperly dismounting while climbing a hill.

WHAT CAN The vehicle could overturn. HOW TO AVOID

HAZARD Maintain steady speed when

climbing a hill. If all forward speed is Keep your weight uphill. Apply the brakes. Lock the parking brake when fully stopped. If the ATV begins rolling 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 and remount, following the procedure

described in the owner’s manual. See page 63.

HAPPEN

THE

lost:

backwards:

SAFETY

Operator Safety

WARNING

POTENTIAL HAZARD Improperly operating over obstacles. WHAT CAN Operating over obstacles could cause loss of control or overturn. HOW TO AVOID THE Before operating in a new area, check for obstacles. Avoid operating over large obstacles such as rocks and fallen

trees when possible. If unavoidable, use extreme caution and always follow proper procedures as outlined in the owner’s manual.

HAPPEN

HAZARD

WARNING

POTENTIAL Skidding or sliding. WHAT CAN Skidding or sliding can cause loss of control. If the tires regain traction unexpectedly, the ATV could overturn. HOW TO AVOID THE On slippery surfaces such as ice, travel slowly and use extra

caution to reduce the chance of skidding or sliding out of control.

HAZARD

HAPPEN

HAZARD

SAFETY

Operator Safety

WARNING

POTENTIAL HAZARD Operating the ATV through deep or fast-flowing water. WHAT CAN Tires may float, causing loss of traction and loss of control,

which could lead to an accident or overturn. HOW TO AVOID THE Avoid operating the ATV through deep or fast-flowing water.

If it’s unavoidable to enter water that exceeds the recommended maximum depth (see page 64), 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.

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.

HAPPEN

HAZARD

WARNING

POTENTIAL Improperly operating in reverse. WHAT CAN The ATV could collide with an obstacle or person, resulting in

severe injury. HOW TO AVOID THE Before shifting into reverse gear, always check for obstacles or

people behind the ATV . When it’s safe to proceed, back slowly.

HAZARD

HAPPEN

HAZARD

SAFETY

Operator Safety

WARNING

POTENTIAL HAZARD Operating this ATV with improper tires, or with improper or uneven

tire pressure. WHAT CAN Use of improper tires, or operation of the ATV with improper or

uneven tire pressure, could cause loss of control or accident. HOW TO AVOID THE Always use the size and type of tires specified for the ATV in the

owner’s manual. Always maintain proper tire pressure as described in the owner’s

manual and on safety decals.

HAPPEN

HAZARD

WARNING

POTENTIAL Operating the ATV with improper modifications. WHAT CAN Improper installation of accessories or modification of the ATV

may cause changes in handling, which could lead to an accident.

HOW TO AVOID THE Never modify the ATV through improper installation or use of

accessories. All parts and accessories added to the vehicle must be genuine Polaris Industries Inc. or equivalent components designed for use on this ATV and should be installed and used according to approved instructions. See your authorized Polaris ATV dealer for more information.

HAZARD

HAPPEN

HAZARD

SAFETY

Operator Safety

WARNING

POTENTIAL HAZARD Overloading the ATV or carrying/towing cargo improperly. WHAT CAN Overloading and towing can cause changes in vehicle handling,

which could lead to loss of control or an accident. HOW TO AVOID THE Never exceed the stated load capacity for this ATV. Cargo should be properly distributed and securely attached. Reduce speed when carrying 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.

HAPPEN

HAZARD

WARNING

POTENTIAL Operating on frozen bodies of water. WHAT CAN Severe injury or death can result if the ATV and/or the operator

fall through the ice. HOW TO AVOID THE Never operate the ATV on a frozen body of water. If you’re

confident that the ice is thick enough and sound enough to support the machine and its operator, as well as the force created by a moving vehicle, exercise extreme caution.

HAZARD

HAPPEN

HAZARD

SAFETY

Operator Safety

WARNING

Operating a damaged ATV can result in an accident with serious injury or death. After any overturn or accident, have a qualified service dealer inspect the entire machine for possible damage, including (but not limited to) brakes, throttle and steering systems.

WARNING

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 away from the exhaust system.

CONTROLS

Engine Electrical Switches

WARNING

Activating the override switch while the throttle is open can cause loss of control, resulting in severe injury or death. Do not activate the override switch while the throttle is open.

Mode/Reverse Override Switch (1) - This vehicle is equipped with a reverse speed limiter system. To gain additional power while backing, depress the override switch. NOTE: The override switch also allows activation of All Wheel Drive (AWD) in reverse, if the AWD switch is on. This switch is also used to toggle through the different modes of the rider information center. See page 45.

Engine Stop Switch (2) - The engine will

OFFOFF

not start or run when the switch is in the

RUN

OFF position. Its purpose is t o 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, including lights. To stop the engine, slide the stop switch either right or left to the OFF position.

CONTROLS

WARNING

Operating an ATV with sticking or improperly 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 for free movement and return before starting the engine. Also check occasionally during operation.

Throttle Lever

Engine speed and vehicle movement are controlled by pressing the throttle lever (1). The throttle lever is spring loaded. Engine speed returns to idle when the lever is released.

This ATV is equipped with Polaris Electronic Throttle Control (ETC), which is designed to reduce the risk of a frozen or stuck throttle. If the throttle cable should stick in an open position when the operator releases the throttle lever, the engine will stop, and power to the rear wheels will cease.

WARNING

The Electronic Throttle Control (ETC) stops the engine in the event of a throttle system malfunction and is provided for your safety. Do not attempt to modify the ETC system or replace it with any after market throttle mechanisms.

CONTROLS

Light Switches

The light switch is located on the left handlebar. It’s used to turn the lights on and off and to switch the lights from HI to LO. NOTE: The lights won’t work unless the key is in the ON position and the shut-off switchisintheRUN position.

WARNING

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 lights. It’s designed for and must be used for off-road use only. Use caution and drive at reduced speeds in conditions of reduced visibility such as fog, rain and darkness.

Brake Lever

The front and rear brakes are applied by squeezing the brake lever (1) toward the handlebar. The front and rear brakes are hydraulically activated disc type brakes that are activated by only one lever.

Always test brake lever travel and master cylinder 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 be corrected before riding. Contact your dealer for proper diagnosis and repairs.

WARNING

Operating the ATV with a spongy brake lever can result in loss of braking, which could cause an accident.

Never operate the ATV with a spongy-feeling brake lever.

CONTROLS

Master Cylinder

The brake fluid in the master cylinder (1), which is located on the left handlebar, should be checked before each ride. The fluid level can be seen through an indicator window (2) on the top of the master cylinder. This eye will appear dark when the fluid level is full. When fluid needs to be added, the eye will be clear.

NOTE: 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.

WARNING

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 causes the boiling temperature of the brake fluid to drop, which can lead to early brake fade and the possibility of accident or severe injury.

CONTROLS

Parking Brake

WARNING

Operating the ATV while the parking brake is engaged could result in an accident and serious injury or death. Always check to be sure the parking brake is disengaged before operating.

Setting the Parking Brake

1. Place the transmission in first gear (or in PARK if equipped).

2. Squeeze and release the brake lever (1) two or three times, then squeeze and hold.

3. Push the park brake lock (2) forward to engage the brake. Release the brake lever.

4. To release the parking brake lock, squeeze and release the brake lever. It will return to its unlocked position.

Important Safeguards

S The parking brake may relax i f left on for a long period of time. Al-

ways block t he 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.

CONTROLS

Auxiliary Brake

WARNING

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 the auxiliary brake. Do not aggressively apply the auxiliary brake when going forward. The rear wheels may skid and slide sideways, causing loss of control and serious injury or death.

Your P olaris ATV has an auxiliary brake (1) for added safety. It’s located on the inside of the right floor board and is operated by the right foot. The auxiliary brake serves as a backup to the main brake system if the main system becomes inoperative.

If the rear wheels slide while using the auxiliary brake, reduce brake pedal pressure to brake the rear wheels without skidding.

Brake F lu id 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.

CONTROLS

Choke

The choke assists in starting a cold engine. Refer to the engine starting procedure on page 53 for correct choke and throttle settings during starting.

Fuel Valve

The fuel valve (1) is located on the left side panel. It has t hree positions:

OFF: For vehicle storage and when transporting.

ON: For normal operation.

RES: For reserve supply if main supply 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 t he 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.

OFF

RES

Fuel Filter

The in-line fuel filter should be replaced by your dealer after every 100 hours of operation, or annually. Do not attempt t o clean the fuel filter.

CONTROLS

Automatic Transmission Gear Selector

The transmission gear selector (1) is located on the right side of the vehicle. Shift patterns vary, depending on your model.

H: High Gear L: Low Gear N: Neutral R: Reverse P: Park (Sportsman 600/700 only)

To shift into HIGH or PARK on the Sportsman 600 or 700, you must first apply the auxiliary brake to activate the high/park lock-out mechanism. When shifting out of HIGH or PARK, it’s not necessary to apply the brake.

400/500 600/700

CAUTION

Shifting gears with the engine speed above idle or while the vehicle is moving could cause transmission damage.

To change gears, stop the vehicle, and with the engine idling, move the lever to the desired gear. Apply the auxiliary brake if shifting into HIGH or PARK on the Sportsman 600 or 700.

Whenever the ATV is left unattended, always place the transmission in first 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

T o 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.

FEATURES

All Wheel Drive (AWD) System

Polaris 4-wheel drive ATVs are equipped with a unique, Polaris-exclusive, AWD system, which is activated by a switch (1) on the right handlebar. When the switchisoff,theATVisin2wheel drive at all times. When the switch is on, the ATV is in AWD and the AWD indicator light in the instrument cluster will be on.

When in AWD, the front gearcase will automatically engage any time the rear wheels lose traction. When the rear wheels regain traction, the front gearcase will automatically disengage.

NOTE: The override switch allows activation of AWD in reverse if the AWD switch is on. See page 36.

There is no limit to the length of time the vehicle may remain in AWD.

Engaging Front Gearcase

The AWD switch may be turned on or off while the vehicle is moving. Initially, the vehicle’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 moving, it will not disengage until the rear wheels regain traction.

Engage the AWD switch before getting into conditions where front wheel drive may be needed. If the rear wheels are spinning, release the throttle before switching to AWD.

CAUTION

Switching to AWD while the rear wheels are spinning may cause severe drive shaft and gearcase damage. Always switch to AWD while the rear wheels have traction or are at rest.

FEATURES

Instrument Cluster

Your ATV is equipped with an instrument cluster that senses vehicle speed from the right front wheel. The instrument cluster measures distance in miles as well as hours of operation. It also includes a reverse speed limiter function 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

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 clean off any gasoline that splashes on the instrument cluster.

FEATURES

Instrument Cluster

Rider Information Center

The rider information center is located in the instrument cluster. All segments will light up for 2.5 seconds at start-up.

NOTE: If the instrument cluster fails to illuminate, a battery over-voltage may have occurred and the instrument cluster may have shut off to protect the electrical system. If this occurs, take the ATV to your Polaris dealer for proper diagnosis.

1. Gear Indicator - As the shift lever is moved, this indicates the gear the transmission is in:

H = High Range

L = Low Range N = Neutral R = Reverse P = Park (if equipped)

2. AWD Indicator - This indicator 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 l ow 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 (lights, cooling fan, accessories) is applied. Driving at a higher RPM or connecting a battery charger will usually clear the warning.

6. Odometer/Tachometer/Tripmeter/ Hour Meter

7. Check Engine Warning Indicator - The word HOT will display alphanumerically when the engine is overheating. Do not continue to operate the ATV if this warning appears or serious engine damage could result.

8. Mode Indicator

FEATURES

Instrument Cluster

Rider Information Center

The rider information center has 4 standard modes: Mode 1 - Odometer Mode 2 - Tripmeter Mode 3 - Total Service Hours Mode 4 - Tachometer The reverse override button on the left handlebar is also the mode

button. NOTE: If using the mode button to program the rider information center, or to toggle through the options, the machine cannot be in reverse.

Mode 1 - Odometer

The odometer records the miles traveled 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 - Hour Meter

This mode logs the total hours t he engine has been in operation.

Mode 4 - Tachometer

The engine RPM is displayed digitally. NOTE: Small fluctuations in the RPM from day to day may be normal because of changes in humidity, temperature and elevation.

FEATURES

Instrument Cluster

Rider Information Center

Diagnostic Mode

The diagnostic mode is for informational purposes only. Please return your ATV to your dealer for all major repairs.

As long as the gauge is 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 key switch off and on. NOTE: Any movement of the tires will also take the machine out of the diagnostic mode.

To enter the diagnostics mode:

1. Turn the key switch off 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.

Screen 1: Battery voltage

Screen 2: Tachometer

Screen 3: AWD diagnostic

This gauge indicates whether or not current is flowing through the AWD coil (only on models with switchable AWD).

Screen 4: Gear circuit diagnostic This screen displays the resistance value (in ohms) being read at the

gear switch input of the gauge.

FEATURES

Instrument Cluster

Rider Information Center

Diagnostic Mode

Screen 5: Programmable service interval The purpose of the programmable service interval is to provide the

consumer and dealer with a convenient reminder for routine maintenance. When your vehicle leaves the factory, this feature is set at 50 hours. You must enable the programmable service interval before it can be used.

Once the service interval mode is set with the hours when service is due, the hours of actual engine operation are subtracted from the set hours until 0 is reached. When the counter reaches 0, the wrench icon will flash quickly for 5 seconds each time the vehicle is started as a reminder that the periodic maintenance is due.

To set the hours, press and hold the mode/override button until the wrench icon flashes. When it begins to flash, release the button. The setting will increase by one hour each time the button is pressed. Pressing and holding the button will allow t he 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 until the count turns over to

0. You can then reset the number. If the service interval is enabled on your ATV and you wish to turn it

off, toggle to the service interval mode. Press and hold the mode button for approximately 7 seconds until the word OFF appears in the Rider Information Center.

Screen 6: Miles/Kilometers toggle The display in the tripmeter and odometer can be changed to display

either kilometers or miles. The current display mode will be shown as KM or MP. To change, hold in the mode button until the letters flash, then press and release the button once. When the display stops flashing, the mode has been set.

OPERATION

Fuel Safety

WARNING

Gasoline is highly flammable and explosive under certain conditions.

S Always exercise extreme caution whenever handling gasoline. S Always refuel with the engine stopped, and outdoors or in a

well ventilated area.

S Do not smoke or allow open flames or sparks in or near the

area where refueling is performed or where gasoline is stored.

S Do not 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 consciousness or death in a short time.

S Turn the fuel valve off whenever the ATV is stored or parked.

WARNING

The engine exhaust from this product contains chemicals known to cause cancer, birth defects or other reproductive harm.

Operate this vehicle only outdoors or in well-ventilated areas.

OPERATION

Break-In Period

The break-in period for your new Polaris ATV is defined as the first ten hours of operation, or the time it takes to use the first two full tanks of gasoline. No single action on your part is as important as following the procedures for a proper break-in. Careful treatment of a new engine will result in more efficient performance and longer life for the engine. Perform the following procedures carefully.

CAUTION

Excessive heat build-up during the first three hours of operation will damage close-fitted engine parts. Do not operate at full throttle or high speeds for extended periods during the first three hours of use.

CAUTION

Mixing brands or using a non-recommended oil may cause serious engine damage. We recommend the use of Polaris Premium 4 synthetic Oil or another 0W-40 API certified SH oil. Never substitute or mix oil brands.

1. Fill the fuel tank with gasoline. See page 42.

2. Check the oil reservoir level on the dipstick. See page 79. Add oil if necessary to maintain the level between the safe and add marks.

3. Drive slowly at first. S elect 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 miles.

OPERATION

Pre-Ride Inspection

WARNING

If a proper inspection is not done before each use, severe injury or death could result. Always inspect the vehicle before each use to ensure it’s in proper operating condition.

Use the following checklist to verify that your vehicle is in proper working condition before each use.

Item/Inspection Procedure

1. Tires - Check condition and pressures.

2. Fuel tank and engine oil level - Fill both to their proper levels.

3. All brakes - Check operation, adjustment and fluid levels (includes auxiliary brake).

4. Throttle - Check for free operation and closing.

5. Headlight/Taillight/Brakelight - Check operation of all indicator lights and switches.

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 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 - Wear a helmet, goggles and protective clothing.

12. Engine coolant - Check for proper level at the recovery bottle.

OPERATION

Starting the Engine

Starting a Cold Engine

WARNING

Engine exhaust contains poisonous carbon monoxide and can cause loss of consciousness resulting in severe injury or death. Never run an engine in an enclosed area.

1. Place the transmission in neutral (or PARK if equipped) and lock the parking brake.

2. Turn the fuel tank valve on.

3. Sit on the vehicle and pull the choke knob out until it stops (1).

NOTE: The variable choke is fully on when the knob is pulled completely out. The choke is off when the knob is pushed completely in. The choke can be adjusted gradually, depending on how much choke is needed for starting. Be sure the choke is off during operation, as excess fuel washing into the engine oil will increase wear on engine components.

4. Turn the engine stop switch to RUN.

NOTE: Do not press the throttle while starting the engine.

5. Turn the 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 allow proper engine warm-up.

7. Vary the engine RPM slightly with the throttle to aid in warm-up. When the engine idles smoothly, push the choke completely in.

CAUTION

Operating the vehicle immediately after starting could cause engine damage. Allow the engine to warm up for several minutes before operating the vehicle.

OPERATION

Starting the Engine

Starting a Warm Engine

Warm engines do not normally require the use of the choke. Using the choke can cause the spark plug to become wet fouled.

1. Position the vehicle on a level surface with the transmission in neutral (or PARK if equipped).

2. Lock the parking brake, turn the fuel tank valve on, sit on the vehicle, and turn the engine stop switch to RUN.

3. If the engine has cooled to a point where it does not readily start, intermittent use of t he choke button (pulled half way out) may be necessary.

4. If 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 sparkplugandtryagain.

Cold Weather Operation

If the ATV is used year-round, check the oil level frequently. A rising oil level could indicate the accumulation of contaminates such as water or excess fuel i n the bottom of the oil tank. Water in the bottom of the tank can lead to engine damage and must be drained. W ater accumulation increases as outside temperature decreases.

See your Polaris dealer for engine heater kits, which provide quicker warm-ups and easier starting in colder weather.

Hauling Cargo

OPERATION

2/3

Your ATV has been designed to carry or tow a certain amount of load. Always read and understand the load distribution warning labels on the vehicle, and never exceed the weight capacities outlined in the specifications 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 heavy cargo to extend belt life.

1/3

OPERATION

Hauling Cargo

WARNING

Hauling cargo improperly can alter vehicle handling and may cause loss of control or brake instability and result in serious injury or death. Always follow these precautions when hauling cargo:

S REDUCE SPEED AND ALLOW GREATER DISTANCES FOR

BRAKING WHEN HAULING CARGO.

S CARGO WEIGHT DISTRIBUTION should be 1/3 on the front

rack and 2/3 on the rear rack. When operating over rough or hilly terrain, reduce speed and cargo to maintain stable driving conditions. Carrying loads on one rack only increases the possibility of vehicle overturn.

S CARRY LOADS AS LOW ON THE RACKS AS POSSIBLE.

Carrying loads high on the racks raises the center of gravity of the vehicle and creates a less stable operating condition.

S SECURE ALL LOADS BEFORE OPERATING. Unsecured

loads can create unstable operating 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 with a loaded vehicle. Avoid terrain or situations that may require backing downhill.

S USE EXTREME CAUTION when operating with loads that

extend over the rack sides. Stability and maneuverability may be adversely affected, causing the vehicle to overturn.

S DO NOT BLOCK THE FRONT HEADLIGHT BEAM when

carrying loads on the front rack.

S DO NOT TRAVEL FASTER THAN THE RECOMMENDED

SPEEDS. Vehicle should never exceed 10 mph (16 kph) while towing a load on a level grass surface. Vehicle speed should never exceed 5 mph (8 kph) when towing loads in rough terrain, while cornering, or while ascending or descending a hill.

OPERATION

Driving Safely

Driving Procedures

1. Sit upright with both feet on the footrests and both hands on the handlebars.

2. Start the engine and allow it 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.

OPERATION

Driving Safely

Making Turns

Your ATV is equipped with a solid rear axle, which drives both rear wheels equally at all times. This means that the wheel on the outside of the turn must travel a greater distance than the inside wheel when turning and the inside tire must slip traction slightly. To turn, steer in the direction of 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 or at excessive speeds can result in vehicle overturn and lead to serious injury. Avoid turning at sharp angles. Never turn at high speeds.

OPERATION

Driving Safely

Driving on Slippery Surfaces

Whenever riding on slippery surfaces such as wet trails or loose gravel, or during freezing weather, follow these precautions:

1. Slow down when entering slippery areas.

2. Maintain a high level of alertness, reading the trail and avoiding quick, sharp turns, which can cause skids.

3. Correct a skid by turning the handlebars i n the direction of the skid and shifting your body weight forward.

4. Driving with All Wheel Drive engaged can assist in controlling the vehicle in slippery areas.

CAUTION

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.

WARNING

Failure to exercise care when operating on slippery surfaces can result in loss of tire traction and cause loss of control, accident, and serious injury or death.

Never apply the brakes during a skid. Do not operate on excessively slippery surfaces. Always reduce speed and use additional caution.

OPERATION

Driving Safely

Traveling Uphill

25_ Ma ximum

Whenever traveling uphill, follow these precautions:

1. Always travel straight uphill.

2. Avoid steep hills (25_ maximum).

3. Keep both feet on the footrests.

4. Transfer your weight forward.

5. Proceed at a steady rate of speed and throttle opening.

6. Remain alert and be prepared to take emergency action. This may include quick dismounting of the vehicle.

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 follow proper

operating procedures outlined in the owner’s manual.

OPERATION

Driving Safely

Sidehilling

WARNING

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 of a hill when possible. Follow proper procedures as outlined in the owner’s manual.

Sidehilling can be a dangerous type of driving and should be avoided if at all possible. If you do enter into a situation where sidehilling is necessary, follow these precautions:

1. Slow down.

2. Lean into the 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.

NOTE: If the vehicle begins to tip, quickly turn the front wheel downhill, if possible, or dismount on the uphill side immediately!

OPERATION

Driving Safely

Traveling Downhill

Whenever descending a hill, follow these precautions:

1. Proceed directly downhill.

2. Transfer your weight to the rear of the vehicle.

3. Slow down.

4. Apply the brakes slightly toaidinslowing. Familiarize yourself with operation of the auxiliary brake in the event

loss of normal service brakes occurs.

WARNING

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

OPERATION

Driving Safely

Turning Around on a Hill

WARNING

Improper hill climbing procedures 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 follow proper

operating procedures outlined in the owner’s manual.

If the vehicle stalls while climbing a hill, never back it down the hill! One maneuver that can be used when you must turn around while climbing a hill is the K-turn:

1. Stop and lock the parking brake while keeping body weight uphill.

2. Leave the transmission in forward and shut off the engine.

3. Dismount on the uphill side of the vehicle, or on the left if the vehicle is pointing straight uphill.

4. Staying uphill of the vehicle, turn the handlebars full l eft.

5. While holding the 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 brake, until the vehicle is on more level ground.

8’

Uphill

OPERATION

Driving Safely

Driving Through Water

Your ATV can operate through water with a maximum recommended depth equal to the bottom of the footrests (1). Follow these procedures when operating through water:

1. Determine water depths and current before crossing.

2. Choose a crossing where both banks have gradual inclines.

3. Proceed slowly, avoiding rocks and obstacles if possible.

4. After crossing, dry the brakes by applying light pressure to the lever until braking action i s normal.

After running the vehicle in water, it’s critical to have it serviced as outlined in the maintenance chart. See page 69. The following areas need special attention: engine oil, transmission oil, front and rear gearcases, and all grease fittings.

CAUTION

Major engine damage can result if the vehicle is not thoroughly inspected after operation in water. Perform the services outlined in the maintenance chart.

If your vehicle becomes immersed or is operated in water that exceeds the footrest level, take it to your dealer for service before starting the engine.

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 it’s impossible to take it to a dealer before starting it, follow the steps described on page 102. Have the vehicle serviced by your dealer at the first opportunity.

OPERATION

Driving Safely

Driving Over Obstacles

Be alert! Look ahead and learn to read the terrain you’re traveling on. Be constantly alert for hazards such as logs, rocks and low hanging branches.

WARNING

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.

OPERATION

Driving Safely

Driving in Reverse

Follow these precautions when operating in reverse:

1. Always avoid backing downhill.

2. Back slowly.

3. When in reverse, apply the brakes lightly for stopping.

4. Avoid turning at sharp angles in reverse.

5. Never open the throttle suddenly while backing.

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 vehicle movement. Use with caution.

Avoid backing on inclines, and avoid turning at sharp angles.

NOTE: Your Polaris ATV is equipped with a reverse speed limiter. The override button should be used with caution as rearward vehicle speed is greatly increased. Do not operate at wide open throttle. Open the throttle just enough to maintain a desired speed.

CAUTION

Excessive throttle operation while in the speed limit mode may cause fuel to build in the exhaust, resulting in engine popping and/or engine damage.

OPERATION

Driving Safely

ParkingonanIncline

Avoid parking on an incline 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.

EMISSION CONTROL SYSTEMS

Noise Emission Control System

TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED! U.S. Federal law prohibits the following acts or the causing thereof: (1) the removal or rendering inoperative by any person other than for

purposes of maintenance, repair, or replacement of any device or element of design incorporated into any new vehicle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use or

(2) the use of the vehicle after such device or element of design has been removed or rendered inoperative by any person.

ACTS PRESUMED TO CONSTITUTE TAMPERING INCLUDE BUT ARE NOT LIMITED TO THE FOLLOWING:

1. Removal, alteration or the puncturing of the m uffler or any engine component that conducts removal of engine exhaust gases.

2. Removal, alteration or the puncturing of any part of the engine air induction system.

3. Replacement of any vehicle parts with parts not in compliance with federal regulations.

4. Lack of proper maintenance.

CAUTION

Exhaust system components are very hot during and after use of the vehicle. Hot components can cause serious burns and fire. Do not touch hot exhaust system components. Use caution when traveling through tall grass, especially dry grass.

USFS Approved Spark Arrestor

Your Polaris ATV has a muffler that was tested and approved i n accordance with the USFS Forest Service Standard 5100-1A.

Exhaust Emission Control System

The exhaust emission control system is composed of efficient carburetor settings with an optimum ignition system. Idle speed can be adjusted with the throttle stop screw. The carburetor must be maintained at Polaris specifications to achieve optimal performance.

Crankcase Emission Control System

This engine is equipped with a closed crankcase system. It allows blow-by gases back to the combustion chamber using the intake system. It does not allow the blow-by gases to enter the atmosphere.

MAINTENANCE AND LUBRICATION

Periodic Maintenance Schedule

Careful periodic maintenance will help keep your vehicle in the safest, most reliable condition. Inspection, adjustment and lubrication of important components are explained in the periodic maintenance schedule. Use the instrument cluster’s programmable service interval mode to help determine when maintenance service is due. See page 49 for instructions.

Maintenance intervals are based upon average riding conditions and an average vehicle speed of approximately 10 miles per 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 adjustment procedures, have a qualified dealer perform these operations.

Maintenance Chart Key

" Perform these operations more often under severe use, such as in

dirty or wet conditions, to purge water or dirt contamination from grease fittings and other critical components.

L Emission Control System Service (California - 4-Cycle)

J Dealer service item.

MAINTENANCE AND LUBRICATION

Periodic Maintenance Schedule

Hours of operation are based on a 10 mph average. If service is due at 20 hours, the equivalent odometer reading would be 200 miles. Perform all services at whichever reading is reached first.

WARNING

Improperly performing the procedures marked with a J could result in component failure and lead to serious injury or death. Have an authorized Polaris dealer perform these services.

Item Hours/

Miles

Brake System Pre-Ride Pre-Ride Inspect Auxiliary Brake Pre-Ride Pre-Ride Inspect Tires Pre-Ride Pre-Ride Inspect Wheels Pre-Ride Pre-Ride Inspect Frame nuts, bolts,

fasteners

Air filter, Pre-cleaner

Coolant level Pre-Ride Pre-Ride Replace coolant every two

Fuel tank and engine oil

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, such as dirty or wet conditions

Pre-Ride Pre-Ride Inspect

Pre-Ride Pre-Ride Inspect; clean

Pre-Ride Pre-Ride Fill to proper levels

Frequency Remarks

years

L Emission Control System Service (California)

J Dealer service item

MAINTENANCE AND LUBRICATION

Periodic Maintenance Schedule

Item Hours/

Miles

" Air box sediment

tube Headlamp Pre-Ride Pre-Ride Check operation daily; ap-

Tail lamp/brake lamp

Air filter, main element

" Transmission oil

level Battery 20 hrs Monthly Check terminals; clean;

Engine breather filter

J Brake pad wear 10 hrs Monthly Inspect periodically " Front and rear

gearcase oil

" General lubrication 50 hrs 3 months Lubricate all fittings, pivots,

Engine oil level/oil change

Oil Filter 100 hrs./

Engine breather

hose

Pre-Ride Pre-Ride Drain deposits whenever

Pre-Ride Pre-Ride Check operation daily; ap-

Weekly Weekly Inspect; replace as needed

20 hrs Monthly Inspect monthly; change

20 hrs Monthly Inspect; replace annually

100 hrs Monthly Check monthly; change

100 hrs / 1000 miles

1000 mi. 100 hrs. 6 months Inspect

Frequency Remarks

visible

ply Polaris dielectric grease to connector when replaced

ply Polaris dielectric grease to socket when replaced

annually

check fluid level if applicable

and as needed

annually

cables, etc.

6 months Check level daily; break-in

service at one month; change oil more often in cold weather

6 months Replace with oil change

MAINTENANCE AND LUBRICATION

Periodic Maintenance Schedule

WARNING

Improperly performing the procedures marked with a J could result in component failure and lead to serious injury or death. Have an authorized Polaris dealer perform these services.

Item Hours/

Miles

Carburetor float bowl

J Throttle Cable/ETC

Switch Choke (enricher)

cable Coolant strength 100 hrs. 6 months Inspect strength seasonal-

J Drive belt 50 hrs. 6 months Inspect; replace as needed " Steering 50 hrs. 6 months Inspect daily; lubricate " Front suspension 50 hrs. 6 months Inspect; lubricate; tighten

" Rear suspension 50 hrs. 6 months Inspect; tighten fasteners " Drive chain(s) 50 hrs. 6 months Inspect daily; adjust and lu-

Spark plug 100 hrs. 12 months Inspect; replace as needed

" More often under severe use, such as dirty or wet conditions

50 hrs. 6 months Drain bowl periodically and

50 hrs. 6 months Inspect; adjust; lubricate;

Frequency Remarks

prior to s torage

replace if necessary

ly; pressure test system annually

fasteners

bricate if needed

L Emission Control System Service (California)

J Dealer service item

MAINTENANCE AND LUBRICATION

Periodic Maintenance Schedule

Item Hours/

Miles

" Rear axle 50 hrs. 6 months Inspect bearings; lube

Ignition Timing 100 hrs. 12 months Inspect; adjust as needed

Fuel system 100

J Fuel filter 100 hrs. 12 months Replace annually

Radiator 100 hrs. 12 months Inspect; clean external sur-

Cooling system hoses

Spark arrestor 100 hrs. 12 months Clean out

J Clutches (drive and

driven) Engine mounts 100 hrs. 12 months Inspect

J Brake fluid 200 hrs. 24 months Change every two years J Front wheel bear-

ings Idle speed As required Adjust

J Toe adjustment As required Periodic inspection; adjust

Headlight aim As required Adjust as needed

hours

100 hrs. 12 months Inspect

100 hrs. 12 months Inspect; clean

300 hrs. 36 months Inspect; replace as needed

Frequency Remarks

12 months Check for leaks at tank

cap, lines, fuel valve, filter, pump and carburetor; replace lines every two years

face

when parts are replaced

MAINTENANCE AND LUBRICATION

Periodic Maintenance Record

Use the following chart to record periodic maintenance.

Maintenance

Interval

Performed

10 hrs. 20 hrs. 50 hrs.

100 hrs.

Servicing

Date

Servicing

Dealer

or Person

Remarks

-NOTES-

MAINTENANCE AND LUBRICATION

Lubrication Guide

NOTE: Hours in the frequency column are based on 10 mph average. If service is due at 20 hours, the equivalent odometer reading would be 200 miles. Perform all services at whichever reading is reached first.

Lubrication Guide Key

" More often under severe use, such as wet or dusty conditions

L Polaris Premium All Season Grease or grease conforming to NLGI

No. 2, such as Conoco S uperlube M or Mobilegrease Special

F Use Polaris Premium U-Joint Lube every 500 miles, before long

periods of storage, or after pressure washing or submerging.

Item Lube Method Frequency

Engine OIl Polaris Premium 4

Brake Fluid DOT 3 Only Maintain level between fill

Transmission Oil (Fig. 1)

Front Gearcase Oil (Fig. 2)

Rear Gearcase Oil (Fig. 3)

Front Prop Shaft Yoke (Fig. 4)

Front Drive Axle (U Joint) (Fig. 5)

Ball Joint (Fig. 6)

Synthetic 0W40

Polaris Premium Synthetic Gear case Lube

Premium Drive Hub Fluid

Premium Synthetic Gearcase Lube (or GL5 80-90 weight gear lube)

FGrease Grease fittings (3 pumps

FGrease Locate grease fitting and

"LGrease

Add to proper level on dipstick.

lines. See page 39.

See page 83 (400/500) or page 85 (600/700).

See page 84 (400/500) or page 86 (600/700).

See page 87 (600/700). Change annually or

maximum)

grease with grease gun.

Locate fitting on back side of struts and grease with grease gun.

Check level daily.

As required; change every two years or 200 hours

Check every 6 months/1000 miles. Change annually or at 100 hours

Change annually or at 100 hours

at 100 hours

Every 3 months or 50 hours

MAINTENANCE AND LUBRICATION

Lubrication Guide

(Fig. 1)

(Fig. 2)

(Fig. 3)

(Fig. 4)

(Fig. 5)

(Fig. 2)

(Fig. 6)

MAINTENANCE AND LUBRICATION

Premium 4 Synthetic Lubricant

Polaris Premium 4 All Season synthetic engine oil has been specially formulated for use in Polaris 4-cycle engines. It’s a fully synthetic, high performance, multi-viscosity oil designed to provide the ultimate in lubrication performance and protection. NOTE: See page 121 for the part numbers of Polaris products.

Premium 4 possesses unsurpassed film strength over the widest possible temperature range. It resists viscosity and frictional 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 l ong as it’s 0W-40. Oil may need to be changed more frequently if Polaris Premium 4 is not used. Follow the manufacturer’s recommendations for ambient temperature operation.

CAUTION

MAINTENANCE AND LUBRICATION

Oil Check

The oil dipstick and fill tube (1) are located on the left side of the vehicle.

1. Position the ATV on a level surface.

2. Start the engine and let it idle for 20-30 seconds.

3. Stop the engine. R emove the dipstick and wipe it dry with a clean cloth. NOTE: If your dipstick is equipped with a lever lock (2), lift the lock to remove the dipstick.

4. Reinstall the dipstick completely, but do not lock it (if equipped). The dipstick must bescrewedcompletelyintokeep 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 reinstalling the

ADD 8 OZ. NORMAL FULL

dipstick, be sure to seat the lever lock (if equipped).

SAFE

ADD 8 OZ

MAINTENANCE AND LUBRICATION

Oil and Filter Change

The recommended oil change interval is 100 hours, 1000 miles, or every six months, whichever comes first. Suggested break-in oil change is at 20 hours, 200 miles, or one month, whichever comes first. Severe use operation requires more frequent service. Severe use includes continuous duty in dusty or wet conditions and cold weather riding. NOTE: Severe use cold weather riding is all riding below 10° F., and riding between 10° F and 30° F when most trips are slow speed and less than five miles. Be sure to change the oil filter whenever changing the oil.

Oil Change (400/500)

1. Position the vehicle on 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 t ank 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 clean and free of burrs, nicks or scratches.

5. Reinstall the drain plug and torque to 14-17 ft. lbs. (19-23 Nm)

6. Disconnect the lower oil delivery hose and remove the screen fitting (3) from the oil tank. Clean and reinstall the fitting, torquing to 25 ft. lbs. Reattach the oil line. NOTE: The fitting threads must be sealed with Loctitet PST 505 or PTFE seal tape. The fitting must also line up with the mark (4) on the rear side of the oil tank.

MAINTENANCE AND LUBRICATION

Oil Change (400/500)

7. Place shop towels beneath the oil filter. Using an oil filter wrench, turn the filter (1) counterclockwise and remove.

8. Lubricate the gasket on the new filter with a film of new engine oil. Check to make sure the gasket is in good condition. Also make sure the gasket from the old filter is not still on the engine.

9. Install the new filter and tighten by hand 1/2 t o 3/4 turn after gasket contacts the engine.

10. Approximately one cup of engine oil will remain in the crankcase. To drain, remove the drain plug on the lower right side of the crankcase. NOTE: The sealing surfaces on the drain plug and crankcase should be clean and free of burrs, nicks or scratches.

11. After draining, reinstall the drain plug.

CAUTION

Loss of oil pump prime could result in engine damage. It’s extremely important to drain, refill and start the engine in an expedient manner. Do not allow the engine to sit without oil for extended periods.

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 two minutes. Stop the engine and inspect for leaks.

15. Recheck the oil level on the dipstick and add oil as necessary to bring it to the recommended level on the dipstick.

16. Dispose of used filter and oil properly.

MAINTENANCE AND LUBRICATION

Oil Change (600/700)

1. Place the vehicle on a level surface.

2. Run the engine for two to three minutes until warm. Stop the engine.

3. Clean the area around the drain plug.

4. Place a drain pan beneath engine crankcase and remove the drain plug.

CAUTION

Hot oil can cause serious burns. Do not allow hot oil to touch skin.

5. Allow the oil t o drain completely.

6. Replace the sealing washer on the drain plug. NOTE: The sealing surfaces on drain plug and crankcase should be clean and free of burrs, nicks or scratches.

7. Reinstall the drain plug and torque to 20 ft. l bs. (27 Nm).

8. Place shop towels beneath the oil filter. Using an oil filter wrench, turn the filter counterclockwise 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 (1.9 l) of recommended oil.

13. Place the gear selector in PARK and set the parking brake.

14. Start the engine and let it idle for one to two minutes. Stop the engine and inspect for leaks.

15. Re-check the oil level on the dipstick and add oil as necessary to bring the level to the upper mark on the dipstick.

16. Dispose of used filter and oil properly.

MAINTENANCE AND LUBRICATION

Transmission Oil (400/500)

The transmission oil level should be checked every six months or 1000 miles (1600 km), whichever comes first. Transmission oil should be changed annually. We recommend the use of Polaris Premium Synthetic Gearcase Lubricant. See page 121 for the part numbers of Polaris products.

Oil Check

On the Sportsman 400 and 500, the transmission oil dipstick (1) is located near the rear brake disc on the right side of the ATV.

1. Position the ATV on a level surface. 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 t he 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 reinstall the drain plug.

5. Add 32 oz. (948 ml) of the recommended transmission oil to bring the level to the full m ark on the fill plug/dipstick. Maintain the oil level in the safe range. NOTE: See page 121 for the part numbers of Polaris products.

6. Reinstall the fill plug/dipstick and check for leaks.

MAINTENANCE AND LUBRICATION

Front Gearcase Oil (400/500)

The front gearcase lubricant level should be checked every six months or 1000 miles (1600 km), whichever comes first. Front gearcase oil should be changed annually. Use Polaris Premium Synthetic Gearcase Lube (or GL5 80-90 weight gear lube). See page 121 for the part numbers of Polaris products.

Oil Check

1. Position 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 oil.

3. Clean and reinstall the drain plug. Torque to 14 ft. lbs. (19 Nm).

4. Add 4 ounces (120 ml) of the recommended gearcase oil.

5. Reinstall the fill plug and check for leaks.

MAINTENANCE AND LUBRICATION

Transmission Oil (600/700)

On the Sportsman 600 and 700, the transmission oil fill plug (1) is located on the right side of the ATV behind the footwell.

Oil Check

1. T o access the fill plug, remove the four screws on the footwell and gently pull outward to remove the footwell.

2. Remove the fill plug and check the oil level. The oil should be maintained 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 properly.

3. Clean and reinstall the drain plug. Torque to 14 ft. lbs. (19 Nm).

4. Remove the fill plug and add 13.5 oz. (399 ml) of the recommended transmission oil to bring the level to the proper level (1 5/8” from the top of the fill plug hole).

5. Replace the fill plug and check for leaks.

6. Reinstall the footwell and screws.

15/8”

MAINTENANCE AND LUBRICATION

Front Gearcase Oil (600/700)

The front gearcase lubricant level should be checked every six months or 1000 miles (1600 km), whichever comes first. Front gearcase oil should be changed annually. We recommend the use of Polaris Premium Hub Drive Fluid. See page 121 for the part numbers of Polaris products.

Oil Check

1. Position the ATV on a level surface.

2. Remove the fill plug (1) and view the oil level. Maintain the oil level even with the bottom of the fill plug hole.

3. Add the recommended gearcase 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 reinstall the drain plug. Torque to 14 ft. lbs. (19 Nm).

4. Add 5 ounces (150 ml) of Polaris

5. Reinstall the fill plug and check for leaks.

Premium Hub Drive Fluid.

MAINTENANCE AND LUBRICATION

Rear Gearcase Oil (600/700)

The rear gearcase lubricant level should be checked every six months or 1000 miles (1600 km), whichever comes first. Rear gearcase oil should be changed annually. Use Polaris Premium Synthetic Gearcase Lube (or GL5 80-90 weight gear lube). NOTE: See page 121 for the part numbers of Polaris products.

Oil Check

1. Position the ATV on a level surface.

2. Remove the fill plug 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 5 ounces (150 ml) of the recommended gearcase oil.

4. Inspect the oil level, which should be maintained level with the bottom of the fill plug hole.

5. Reinstall the fill plug. Torque to 14 ft. lbs. (19 Nm) and check for leaks.

MAINTENANCE AND LUBRICATION

Engine Cooling System

Coolant Level

The recovery bottle (1) is located on the left side of the machine. To access the recovery bottle, remove the left side panel as outlined on page 93.

The fluid level must be maintained between the minimum and maximum marks on the bottle (when the fluid is cool).

The engine coolant level is controlled or maintained by the recovery system. The recovery system components are the recovery bottle, radiator filler neck, radiator pressure cap and connecting hose.

As coolant operating temperature increases, the expanding (heated) excess coolant is forced out of the radiator, 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 t he recovery bottle.

Polaris recommends the use of Polaris Premium 60/40 anti-freeze/coolant or a 50/50 mixture of high quality aluminum compatible anti-freeze/coolant and distilled water. See page 121 for the part numbers of Polaris products.

NOTE: Polaris Premium 60/40 is already premixed and ready to use. Do not dilute with water.

NOTE: Always follow the manufacturer’s mixing recommendations for the freeze protection required in your area.

MAINTENANCE AND LUBRICATION

Engine Cooling System

WARNING

Escaping steam can cause severe burns. Never remove the pressure cap while the engine is warm or hot. Always allow the engine to cool before removing the pressure cap.

Radiator Coolant Level

NOTE: This procedure is required only if the cooling system has been drained for maintenance and/or repair. However, if the recovery bottle has run dry, the level in the radiator should be i nspected and coolant added if necessary.

1. Using the tool provided, remove the four screws securing the front rack (1). Remove the front cover (2) by placing your fingers under the front of the cover and pulling upward.

2. Remove the pressure cap.

3. Using a funnel, slowly add coolant as necessary through the radiator filler neck.

4. Replace the pressure cap and secure the front cover and rack.

NOTE: Use of a non-standard pressure cap will 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 quality aluminum compatible anti-freeze/coolant and distilled water. Polaris Premium 60/40 is already premixed and ready to use. Do not dilute with water. See page 121 for the part numbers of Polaris products.

NOTE: Always follow the manufacturer’s mixing recommendations for the freeze protection required in your area.

MAINTENANCE AND LUBRICATION

Front Brake

WARNING

The front brakes are hydraulic disc brakes. They’re activated by moving the brake lever toward the handlebar. These brakes are self-adjusting.

The following checks are recommended to keep the brake system in good operating condition. Check more often if brakes are used heavily under normal operation.

1. Always keep brake fluid at an adequate level (see page 39). NOTE: Under normal functioning the diaphragm extends into the reservoir as fluid level drops. If the fluid level is low and the diaphragm is not extended, a leak is likely and the diaphragm should be replaced. Always fill the reservoir as needed whenever the cover is loosened or removed to ensure proper diaphragm operation. Use Polaris DOT 3 brake fluid (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 worn to 3/64″ (.1 cm), or about the thickness of a U.S. dime.

3/64″ (.1 cm)

MAINTENANCE AND LUBRICATION

Rear Brake

The rear brake is a hydraulic disc brake and is activated by the same lever that activates the front brake system. The rear brake system is self-adjusting and requires no maintenance other than periodic checks of the pads for wear.

Pads should be changed when worn to 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 i s 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 adjustment.

NOTE: Since this is a rear brake only, it will not be as effective as the all wheel system.

3/64″ (.1 cm)

MAINTENANCE AND LUBRICATION

Toe Alignment

WARNING

Severe injury or death can result from improper toe alignment and adjustment. Do not attempt to adjust tie rod alignment. All tie rod adjustments should be performed by an authorized Polaris dealer.

Use the following procedure to check the toe alignment of the vehicle. The recommended toe alignment is 1/8″ to 1/4″ toe out.

1. Set the handlebars in a straight-ahead position. NOTE: The steering frog can be used as an indicator of whether the handlebars are straight. The frog should always point straight back from the steering post.

2. Place stands (1) in front of the vehicle, perpendicular to the rear tires. See illustration.

3. Tie an elastic string around the stands, m aking sure the string just touches the side surface 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″ (.2to.3cm) 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 should be checked periodically for loose nuts and bolts. If loose nuts and bolts are found, see your Polaris dealer for service before operating the vehicle.

MAINTENANCE AND LUBRICATION

Side Panel Removal

NOTE: Side panel removal may be difficult until the locking tabs and receivers have been snapped and unsnapped a few times.

1. Remove the seat.

2. Grasp the rear of the side panel near the rear cab. With a quick and firm motion, pull the panel forward and 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 twotabs. Thenpulluponthe 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 tabs lock. Bend the rear of the side panel and insert the two tabs into the rear cab.

Step 2

Step 3

Step 4

MAINTENANCE AND LUBRICATION

WARNING

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 when replacing tires.

Make sure the wheels are installed properly. Always replace tires when the tread depth measures 1/8″ (.3 cm)

or less.

Tire Tread Depth

Always replace tires when tread depth is worn to 1/8″ (.3 cm) or less. See illustration.

Wheel Removal

1. Stop the engine, place the transmission in gear (or in PARK if equipped) and lock the parking brake.

2. Loosen the wheel nuts slightly.

3. Elevate the side of the vehicle by placing a suitable stand under the footrest frame.

4. Remove the wheel nuts and remove the wheel.

1/8I (.3 cm)

MAINTENANCE AND LUBRICATION

Wheel Installation

1. Place the transmission in gear (or in PARK if equipped) and lock the parking brake.

2. Place the wheel on the wheel hub with the valve stem toward the outside and rotation arrows on the tire pointing toward forward rotation.

3. Install the wheel nuts and finger tighten.

4. Lower the vehicle to the ground.

5. T orque the wheel nuts according to the wheel nut torque specifications chart.

NOTE: All nuts that have a cotter pin installed m ust 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 Nm)

Front Wheel Hub Tightening

Front wheel bearing tightness and spindle nut retention are critical component operations. All service must be performed by your authorized Polaris dealer.

MAINTENANCE AND LUBRICATION

Filter Systems

Air Filter Service

1. Remove the seat, release the air box cover clips, and remove the air box cover.

2. Loosen the clamp and remove the filter.

3. Remove the fabric type pre-filter (1) from the main filter (2). Wash the pre-filter in soapy water, then rinse and let dry.

4. Reinstall the pre-filter over the main filter. (Replace the main filter if needed.)

5. Reinstall t he filter into t he air box and tighten the clamp. Do not over tighten the clamp, as filter damage could occur.

6. Reinstall the air box cover and the seat.

Breather Filter/Hose

1. T o 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. Replace if needed.

4. Check the hoses for cracks, deterioration, abrasion, or leaks. Replace as needed.

5. Reinstall t he filter and secure the clamps. NOTE: The filter is effective with the arrow pointing in either direction.

CAUTION

Operation of your vehicle without a breather filter can cause engine damage. Always reinstall the breather filter after removing for service.

MAINTENANCE AND LUBRICATION

Lights

When servicing a halogen lamp, don’t touch the lamp with bare fingers. Oil from your skin leaves a residue, causing a hot spot that will shorten the life of the lamp.

WARNING

Poor lighting while driving can result in severe injury or death. Headlight and taillight lenses become dirty during normal operation. Wash the headlights frequently to maintain lighting quality.

Hot components can cause serious burns to skin. Do not service the headlamps until they’ve cooled sufficiently.

Headlight Lamp Replacement

1. Remove the two screws on the lower front corners of the headlight pod.

2. Using a small flat-blade screwdriver, push in on the lock tab through the two small openings at the front of the headlight pod.

3. Lift the pod slightly while depressing the tabs.

4. Remove the screw in the back of the headlight pod.

5. Lift the pod cover and disconnect the speedometer harnesses from the speedometer. 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 socket before installing the new bulb. Make sure the tab on the lamp locates properly in the housing.

MAINTENANCE AND LUBRICATION

Lights

High Beam Adjustment

The headlight beam can be adjusted to any position desired by turning the adjusting knob on the bottom right side of the headlight pod.

1. Position the vehicle on a level surface with the headlight approximately 25 ft. (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 headlight switch t o 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 clockwise or counterclockwise.

Snap pins into tabs

Position knob in slot and secure in locking tabs

Adjustment Knob Stop

Slip o-ring over pin

Route plug over handlebar

Polaris Sportsman S User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual