Polaris Sportsman S User Manual

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

+ 109 hidden pages