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1
WELCOME
Thank you for choosing Polaris, and welcome to our world-wide
family of Polaris enthusiasts. Polaris proudly produces an exciting line
of recreational products, including snowmobiles, all-terrain vehicles,
personal watercraft, utility vehicles, and Victory motorcycles.
We believe Polaris sets the standard of excellence for all recreational
vehicles manufactured in the world today. Many years of experience in
engineering, design, and development have gone into making your
Polaris vehicle the finest machine we’ve ever produced.
Follow the instructions and recommendations in this Owner’s Manual
for safe and enjoyable operation of your vehicle. Your Owner’s Manual
contains instructions for minor maintenance. Major repairs are covered
in the Polaris Service Manual and should be performed by a Factory
Certified MSD (Master Service Dealer) Technician.
Your Polaris dealer knows your vehicle best and is interested in your
complete satisfaction. Return to your dealership for all of your service
needs during, and after, the warranty period.
Polaris also takes great pride in our PAA (Parts Apparel and
Accessories) which are available on our online store
www.purepolaris.com. Have your accessories and clothing delivered
right to your door!
Polaris and Polaris The Way Out are registered trademarks of Polaris
Industries Inc.
Copyright 2002
Polaris Industries Inc.
All Rights ReservedPrinted in the U.S.A.
2
WARNING
Failure to follow the warnings contained in this manual can result
in severe injury or death.
A Polaris ATV Pro 500 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 Pro 500.
Age Restrictions
This vehicle is an ADULT VEHICLE ONLY. Operation is prohibited
for anyone under 16 years of age.
Know Your Vehicle
As the operator of the vehicle, you are responsible for your personal
safety, the safety of others, and the protection of our environment.
Read and understand your owner’s manual, which includes valuable
information about all aspects of your vehicle, including safe operating
procedures.
Safety Training
When you purchased your new ATV, your dealer offered a hands-on
safety training course that covers all aspects of vehicle safety. You
were also provided with printed materials that explain safe operating
procedures. You should review this information on a regular basis.
If you purchased a used Polaris ATV from a party other than a Polaris
dealer, you can request this free safety training from any authorized
Polaris dealer.
NOTE: Illustrations used in this manual are for general representation
only. Your model may differ.
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. If your vehicle is stolen, these numbers are essential
to its recovery and identification.
NOTE: Record your vehicle’s ID numbers in the spaces provided.
Remove the spare key and store it in a safe place. Your key can be
duplicated only by mating a Polaris key blank with an existing key.
NOTE: If both keys are lost, see your dealer for ignition switch
replacement.
Shift TypeSide Lever (High, Low, Neutral, Reverse,
Park)
Gear Reduction - Low7.5/1
Gear Reduction - Reverse5.11/1
Gear Reduction - High2.89/1
Drive Ratio - Front:3.82/1
Drive Ratio - Final3.10/1
Tire Size - Front25 x 8 - 12
Tire Size - Rear25 x 11 - 12
Front BrakeHydraulic Disc
Rear BrakeHydraulic
Parking BrakeHydraulic lock, all wheel
Headlight (watts)1 - Single Beam on Handlebar (50)
2 - Single Beam on Grill (27)
Taillights (watts)8.26
Brake Light (watts)26.9
Instrument ClusterLCD
Clutching and Jetting Charts
AltitudeAMBIENT
TEMPERATURE
Meters
(Feet)
AltitudeShift
Meters
(Feet)
(6000-12000)
8
0-1800
(0-6000)
1800-3700
(6000-12000)
0-1800
(0-6000)
1800-3700
Weight
20-56
PN 5631315
20-54
PN 5631214
EBS models require no helix / spring adjustment
Below 40° F
Below 5° C
175162.5
150140
Drive Clutch
Spring
Blue/Green
PN 7041157
Blue/Green
PN 7041157
Driven
Clutch
Spring
White/Yellow
PN 7041635
White/Yellow
PN 7041635
+40°Fand above
+5°C to & above
Helix*
EBS
PN 5132751
EBS
PN 5132751
SAFETY
Understanding Warnings
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.
9
SAFETY
Key Safety Issues
Protect Your Sport
Know all local, state/province riding laws;
Respect your vehicle;
Respect the environment; and
You will gain the respect of others.
We also advise you to strictly follow the recommended maintenance
program as outlined. This preventive maintenance program is designed
to ensure that all critical components on this ATV are thoroughly
inspected at various intervals.
All information in this manual is based upon the latest product data and
specifications available at the time of printing. Polaris Industries Inc.
reserves the right to make product changes and improvements which
may affect illustrations or explanations.
No part of this manual shall be reproduced or used without the written
permission of Polaris Industries Inc.
Illustrations included in this manual are general representations of
parts having a similar function. Your model may differ.
AN ATV IS NOT A TOY AND CAN BE HAZARDOUS TO
OPERATE. An ATV handles differently from other vehicles
including motorcycles and cars. A collision or rollover can occur
quickly, even during routine maneuvers such as turning and driving on
hills or over obstacles, if you fail to take proper precautions.
10
SAFETY
Key Safety Issues
SERIOUS INJURY OR DEATH can result if you do not
follow these instructions:
Read this manual and all labels carefully and follow the operating
procedures described.
Never operate an ATV without proper instruction. Take a training
course. Beginners should receive training from a certified instruc-
tor. Contact an authorized Polaris ATV dealer or call Polaris at
1-800-342-3764 to find out about the training courses nearest you.
Never allow anyone under 16 years of age to operate this ATV.
Never permit a guest to operate this ATV unless the guest has read
this manual and all product labels, and has completed a certified
training course.
Always avoid operating an ATV on any paved surfaces, including
sidewalks, driveways, parking lots and streets.
Never operate an ATV on any public street, road or highway, even a
dirt or gravel one.
Never operate an ATV without wearing an approved helmet that fits
properly. You should also wear eye protection (goggles or face
shield), gloves, boots, long-sleeved shirt or jacket, and long pants.
Never consume alcohol or drugs before or while operating this
AT V.
Never operate at excessive speeds. Always travel at a speed which
is proper for the terrain, visibility and operating conditions, and
your experience.
Never attempt wheelies, jumps or other stunts.
Always inspect your ATV each time you use it to make sure it is in
safe operating condition. Always follow the inspection and maintenance procedures and schedules described in this manual.
Always keep both hands on the handlebars and both feet on the
footrests of the ATV during operation.
Always go slowly and be extra careful when operating on unfamil-
iar terrain. Always be alert to changing terrain conditions when
operating the ATV.
Never operate on excessively rough, slippery or loose terrain.
Always follow proper procedures for turning as described in this
manual. Practice turning at low speeds before attempting to turn at
faster speeds. Do not turn at excessive speed.
Always have the ATV checked by an authorized Polaris dealer if it
has been involved in an accident.
11
SAFETY
Key Safety Issues
Never operate the ATV on hills too steep for the ATV or for your
abilities. Practice on smaller hills before attempting larger hills.
Always follow proper procedures for climbing hills as described in
this manual. Check the terrain carefully before you start up any
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 any hill at
high speed.
Always follow proper procedures for going down hills and for brak-
ing on hills as described in this manual. Check the terrain carefully before you start down any 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.
Go straight down the hill where possible.
Always follow proper procedures for crossing the side of a hill as
described in this manual. 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 have
mastered the turning technique described in this manual on level
ground. Avoid crossing the side of a steep hill if possible.
Always use proper procedures if you stall or roll backwards when
climbing a hill. To avoid stalling, maintain a steady speed when
climbing a hill. If you stall or roll backwards, follow the special
procedure for braking described in this manual. Dismount on the
uphill side or to either side if pointed straight uphill. Turn the
ATV around and remount, following the procedure described in
this manual.
Always check for obstacles before operating in a new area. Never
attempt to operate over large obstacles, such as large rocks or fallen
trees. Always follow proper procedures when operating over obstacles as described in this manual.
Always be careful of skidding or sliding. On slippery surfaces,
such as ice, go slowly and be very cautious in order to reduce the
chance of skidding or sliding out of control.
Avoid operating the ATV through deep or fast flowing water. If
you cannot avoid water which exceeds the recommended maximum depth (pg. 78), go slowly, balance your weight carefully
avoiding sudden movements, 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. Test your brakes
after leaving water. If necessary apply them lightly several times
to let friction dry out the pads.
12
SAFETY
Key Safety Issues
Always be sure there are no obstacles or people behind you when
you operate in reverse. When it is safe to proceed in reverse, go
slowly. Avoid turning at sharp angles in reverse.
Always use the size and type tires specified in this manual. Always
maintain proper tire pressure as described in this manual.
Never modify an ATV through improper installation or use of ac-
cessories.
Never exceed the stated load capacity for an ATV. Cargo should be
properly distributed and securely attached. Reduce speed and follow instructions in this manual for carrying cargo or pulling a trailer. Allow greater distance for braking.
FOR MORE INFORMATION ABOUT ATV SAFETY, call the
Consumer Product Safety Commission at 1-800-638-2772, or Polaris
at 1-800-342-3764.
Additional Important Information...
Due to our concern for the safety of our customers and the general
public, Polaris hereby strongly recommends and requests that
consumers not have installed on a Polaris ATV any equipment which is
intended to increase the speed or power of the vehicle; or make any
other modifications to the vehicle for these purposes. Any
modifications to the original equipment of the ATV substantially
increase the risk of bodily injury. Please be aware that these
modifications may create a substantial safety hazard.
Polaris hereby informs you that the warranty on your ATV is
terminated if any such equipment has been added to the ATV or any
modifications have been made to the ATV which increase its speed or
power.
We also advise you to strictly follow the recommended maintenance
program outlined in this manual. This preventive maintenance
program is designed to ensure that all critical components on the ATV
are thoroughly inspected by your dealer at various mileage intervals.
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 ATV.
Be certain any accessories added to this ATV have been approved by
Polaris.
Familiarize yourself with their function and affect on the ATV.
13
SAFETY
Safety Decals and Locations
NOTE:
Warning decals have been placed on the vehicle for your protection.
Read and follow the instructions on each decal carefully. In the event
any decal becomes illegible or comes off, contact your Polaris dealer
for a replacement. Any safety decal needing replacement will be
provided by Polaris at no charge. The part number is printed on the
decal.
1
14
Safety Decals and Locations
WARNING
1
SAFETY
IF OWNER’S MANUAL IS MISSING, CONTACT
YOUR POLARIS DEALER FOR A REPLACEMENT.
1997, 2000
7079083
15
SAFETY
Safety Decals and Locations
3
2
16
Safety Decals and Locations
SAFETY
2
WARNING
UNDER
Operating this ATV if you are under the age
of 16 increases your chance of severe injury
or death.
NEVER operate this ATV if you are under
age 16.
7078253
3
WARNING
Never operate this ATV on HILLS steeper than 25 degrees
To prevent flipover on hilly terrain, when going up or down,
use throttle and brakes gradually.
REVERSE operation can be dangerous even at low speeds.
Steering becomes difficult. To prevent flipover, avoid sudden
braking or sharp turns.
Use OVERRIDE for reverse speed limiter with caution. To prevent
loss of control, never activate override button with open throttle.
PARKING BRAKE may relax when used for more than 5 minutes.
When parking on grades, leave shift in forward.
25°
7079085
17
SAFETY
Safety Decals and Locations
4
18
5
6
Safety Decals and Locations
6
(on rear of seat)
WARNING
SAFETY
4
5
IMPROPER TIRE PRESSURE OR OVERLOADING can cause loss
of control resulting in SEVERE INJURY OR DEATH.
TIRE PRESSURE IN PSI (KPa): FRONT 5 (34,5) REAR 5 (34,5)
MAXIMUM WEIGHT CAPACITY (Gross Vehicle Weight)
INCLUDING MACHINE, DRIVER AND CARGO IS 1200 LBS.
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
19
SAFETY
Safety Decals and Locations
8
(Under Seat)
7
7
Operation of this vehicle
without the air filter element
will severely damage the engine.
Clean pre-filter element often, more
frequent cleaning required
in dusty conditions. Do not
operate vehicle without pre-filter.
Operation of this vehicle without
engine breather filter(s) can cause
engine damage. Consult owner’s
manual or dealer for details.
Moving parts hazard under belt-clutch guard. To
prevent serious injury, do not operate vehicle with
guard removed.
8
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.
20
ATTENTION
and adjustments are required
depending on temperature and
altitude. See your Owner’s Manual.
40 to 80 F. at 0-3000 feet
(5 to 27 C. at 0-900 meters).
WARNING
NO STEP
Specific
carburetor jetting
Factory setting:
7079902
7078689
Safety Decals and Locations
SAFETY
9
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.
AWD Models
9
9
WARNING
DO NOT TOW FROM RACK OR BUMPER.
Vehicle damage or tipover may result causing severe
injury or death. Tow only from tow hooks or hitch.
Maximum Rack Loads: Front 90 lbs. Rear 180 Lbs
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 VEHICLE 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.
MANUFACTURED
BY: POLARIS IND INC.
DATE:
VIN:
PRINTED IN U.S.A.
7170021
7078472
TRAILER MAX WEIGHT:
1225 LBS. (556 KG) ON LEVEL GROUND
850 LBS. (368 KG) UP TO 15° GRADE
HITCH MAX. VERTICAL WEIGHT: 35 LBS. (16KG)
7078261
21
SAFETY
Safe Riding Gear
Always wear clothing suited to the type of riding you are doing. ATV
riding requires special protective clothing which will make you feel
more comfortable and reduce chances 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 which
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 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).
1
2
3
5
4
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 type boots with
heels, such as moto-cross boots.
5. Clothing
To protect your body, long sleeves and pants should always be worn.
Riding pants with kneepads, a jersey and shoulder pads provide the
best protection.
22
Operator Safety
WARNING
POTENTIAL HAZARD
Operating this ATV without proper instruction.
WHAT CAN HAPPEN
The risk of an accident is greatly increased if the operator
does not know how to operate the ATV properly in different
situations and on different types of terrain.
HOW TO AVOID THE HAZARD
Beginning and inexperienced operators should complete the
certified training course offered by Polaris Industries Inc.
They should then 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.
SAFETY
WARNING
POTENTIAL HAZARD
Failure to follow the age recommendations for this ATV.
WHAT CAN HAPPEN
Use by children of ATVs that are not recommended for their age
can lead to severe injury or death of the child.
Even though a child may be within the age group for which some
ATVs are recommended, he or she may not have the skills,
abilities, or judgment needed to operate the ATV safely and may
be involved in a serious accident.
HOW TO AVOID THE HAZARD
No one under 16 should operate a Polaris ATV.
23
SAFETY
Operator Safety
WARNING
POTENTIAL HAZARD
Carrying a passenger on this ATV.
WHAT CAN HAPPEN
Greatly reduces your ability to balance and control this ATV.
Could cause an accident, resulting in harm to you and/or your
passenger.
HOW TO AVOID THE HAZARD
Never carry a passenger. The long seat is to allow the
operator to shift position as needed during operation. It is not
for carrying passengers.
24
Operator Safety
WARNING
POTENTIAL HAZARD
Operating this ATV on paved surfaces, including sidewalks,
paths, parking lots, and driveways.
WHAT CAN HAPPEN
The ATV tires are designed for off-road use. Paved surfaces
may seriously affect handling and control of the ATV, and may
cause the vehicle to go out of control.
HOW TO AVOID THE HAZARD
Avoid operating the ATV on pavement whenever possible. If
you must ride on a paved surface, go slowly and do not make
sudden turns or stops.
SAFETY
25
SAFETY
Operator Safety
WARNING
POTENTIAL HAZARD
Operating this ATV on public streets, roads or highways.
WHAT CAN HAPPEN
You can collide with another vehicle.
HOW TO AVOID THE HAZARD
Never operate this ATV on any public street, road or highway,
even a dirt or gravel one.
In many states it is illegal to operate ATVs on public streets,
roads and highways.
26
Operator Safety
WARNING
POTENTIAL HAZARD
Operating this ATV without wearing an approved helmet, eye
protection and protective clothing.
WHAT CAN HAPPEN
Operating without an approved helmet increases your
chances of a severe head injury or death in the event of an
accident.
Operating without eye protection can result in an accident and
increases your chances of a severe injury in the event of an
accident.
HOW TO AVOID THE HAZARD
Always wear an approved helmet which fits properly.
You should also wear: eye protection (goggles or face shield);
gloves; boots; long-sleeved shirt or jacket; and long pants.
SAFETY
27
SAFETY
Operator Safety
WARNING
POTENTIAL HAZARD
Operating this ATV after consuming alcohol or drugs.
WHAT CAN HAPPEN
Could seriously affect your judgment.
Could cause you to react more slowly.
Could affect your balance and perception.
Could result in an accident.
HOW TO AVOID THE HAZARD
Never consume alcohol or drugs before or while driving this
ATV.
WARNING
POTENTIAL HAZARD
Operating this ATV at excessive speeds.
WHAT CAN HAPPEN
Increases your chances of losing control of the ATV, which can
result in an accident.
HOW TO AVOID THE HAZARD
Always travel at a speed which is proper for the terrain, visibility
and operating conditions; and your experience.
28
Operator Safety
SAFETY
WARNING
POTENTIAL HAZARD
Attempting wheelies, jumps and other stunts.
WHAT CAN HAPPEN
Increases the chance of an accident, including an overturn.
HOW TO AVOID THE HAZARD
Never attempt stunts, such as wheelies or jumps. Don’t try to
show off.
29
SAFETY
Operator Safety
WARNING
POTENTIAL HAZARD
Failure to inspect the ATV before operating.
Failure to properly maintain the ATV.
WHAT CAN HAPPEN
Increases the possibility of an accident or equipment damage.
HOW TO AVOID THE HAZARD
Always inspect your ATV each time you use it to make sure
the ATV is in safe operating condition.
Always follow the inspection and maintenance procedures and
schedules described in the Owner’s Manual.
WARNING
POTENTIAL HAZARD
Removing hands from handlebars or feet from footrests
during operation.
WHAT CAN HAPPEN
Removing even one hand or foot can reduce your ability to
control the ATV or could cause you to lose your balance
and fall off the ATV. If you remove a foot from the footrest,
your foot or leg may come into contact with the rear
wheels, which could injure you or cause an accident.
HOW TO AVOID THE HAZARD
Always keep both hands on the handlebars and both feet
on the footrests of your ATV during operation.
30
Operator Safety
WARNING
POTENTIAL HAZARD
Failure to use extra care when operating this ATV on unfamiliar
terrain.
WHAT CAN HAPPEN
You can come upon hidden rocks, bumps, or holes, without
enough time to react.
Could result in the ATV overturning or going out of control.
HOW TO AVOID THE HAZARD
Go slowly and be extra careful when operating on unfamiliar
terrain.
Always be alert to changing terrain conditions when operating
the ATV.
SAFETY
31
SAFETY
Operator Safety
WARNING
POTENTIAL HAZARD
Failure to use extra care when operating on excessively
rough, slippery or loose terrain.
WHAT CAN HAPPEN
Could cause loss of traction or vehicle control, which could
result in an accident, including an overturn.
HOW TO AVOID THE HAZARD
Do not operate on excessively rough, slippery or loose
terrain until you have learned and practiced the skills
necessary to control the ATV on such terrain.
Always be especially cautious on these kinds of terrain.
32
Operator Safety
WARNING
POTENTIAL HAZARD
Turning improperly.
WHAT CAN HAPPEN
ATV could go out of control, causing a collision or overturn.
HOW TO AVOID THE HAZARD
Always follow proper procedures for turning as described in
the Owner’s Manual. See page 72 .
Practice turning at low speeds before attempting to turn at
faster speeds.
Do not turn at excessive speed.
WARNING
SAFETY
POTENTIAL HAZARD
Operating on excessively steep hills.
WHAT CAN HAPPEN
The vehicle can overturn more easily on extremely steep hills
than on level surfaces or small hills.
HOW TO AVOID THE HAZARD
Never operate the ATV on hills too steep for the ATV or for
your abilities.
Practice on smaller hills before attempting large hills.
Never operate ATV on hills steeper than 25.
33
SAFETY
Operator Safety
WARNING
POTENTIAL HAZARD
Climbing hills improperly.
WHAT CAN HAPPEN
Could cause loss of control or cause ATV to overturn.
HOW TO AVOID THE HAZARD
Always follow proper procedures for climbing hills as described
in the Owner’s Manual. See pages 74 through 77.
Always check the terrain carefully before you start up any hill.
Never climb hills with excessively slippery or loose surfaces.
Shift your weight forward.
Never open the throttle suddenly. 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.
34
Operator Safety
WARNING
POTENTIAL HAZARD
Going down a hill improperly.
WHAT CAN HAPPEN
Could cause loss of control or cause ATV to overturn.
HOW TO AVOID THE HAZARD
Always follow proper procedures for going down hills as
described in the Owner’s Manual. See page 76. NOTE: A
special technique is required when braking as you go downhill.
Always check the terrain carefully before you start down any
hill.
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. Go straight down the hill
where possible.
SAFETY
35
SAFETY
Operator Safety
WARNING
POTENTIAL HAZARD
Improperly crossing hills or turning on hills.
WHAT CAN HAPPEN
Could cause loss of control or cause ATV to overturn.
HOW TO AVOID THE HAZARD
Never attempt to turn the ATV around on any hill until you have
mastered the turning technique as described in the Owner’s
Manual on level ground. See page 77. Be very careful when
turning on any hill.
Avoid crossing the side of a steep hill if possible.
When crossing the side of a hill:
Always follow proper procedures as described in the Owner’s
Manual.
Avoid hills with excessively slippery or loose surfaces.
Shift your weight to the uphill side of the ATV.
36
SAFETY
Operator Safety
WARNING
POTENTIAL HAZARD
Stalling, rolling backwards or
improperly dismounting while
climbing a hill.
WHAT CAN HAPPEN
Could result in ATV
overturning.
HOW TO AVOID THE
HAZARD
Maintain steady speed when
climbing a hill.
If you lose all forward speed:
Keep weight uphill.
Apply the brakes.
Lock parking brake after you are stopped.
If you begin rolling backwards:
Keep weight uphill; never apply engine power.
Never apply the rear brake while rolling backwards.
Apply the single-lever brake gradually.
When fully stopped, apply rear brake as well, and then lock
parking brake.
Dismount on uphill side, or to either side if pointed straight uphill.
Turn the ATV around and remount, following the procedure
described in the Owner’s Manual. See page 77.
37
SAFETY
Operator Safety
WARNING
POTENTIAL HAZARD
Improperly operating over obstacles.
WHAT CAN HAPPEN
Could cause loss of control or a collision. Could cause the ATV
to overturn.
HOW TO AVOID THE HAZARD
Before operating in a new area, check for obstacles.
Use extreme caution when riding over large obstacles, such as
large rocks or fallen trees.
If you cannot avoid obstacles, always follow proper procedures
as described in the Owner’s Manual.
WARNING
POTENTIAL HAZARD
Skidding or sliding.
WHAT CAN HAPPEN
You may lose control of the ATV.
You may also regain traction unexpectedly, which may cause the
ATV to overturn.
HOW TO AVOID THE HAZARD
On slippery surfaces, such as ice, go slowly and be very
cautious in order to reduce the chance of skidding or sliding out
of control.
38
SAFETY
Operator Safety
WARNING
POTENTIAL HAZARD
Operating this ATV through deep or fast flowing water.
WHAT CAN HAPPEN
Tires may float, causing loss of traction and loss of control,
which could lead to an accident.
HOW TO AVOID THE HAZARD
Avoid operating the ATV through deep or fast flowing water. If
you cannot avoid water which exceeds the recommended
maximum depth (pg 78), go slowly, balance your weight
carefully avoiding sudden movements, maintain a slow and
steady forward motion, do not make sudden turns or stops,
and do not make sudden throttle changes.
Remember that wet brakes may have reduced stopping ability.
Test your brakes after leaving water. If necessary, apply them
several times to let friction dry out the pads.
WARNING
POTENTIAL HAZARD
Improperly operating in reverse.
WHAT CAN HAPPEN
You could hit an obstacle or person behind you, resulting in
severe injury.
HOW TO AVOID THE HAZARD
When you select reverse gear, make sure there are no
obstacles or people behind you. When it is safe to proceed,
go slowly.
39
SAFETY
Operator Safety
WARNING
POTENTIAL HAZARD
Operating this ATV with improper tires, or with improper or
uneven tire pressure.
WHAT CAN HAPPEN
Use of improper tires on this ATV, or operation of this ATV
with improper or uneven tire pressure, may cause loss of
control, and increases the risk of an accident.
HOW TO AVOID THE HAZARD
Always use the correct size, type, and pressure as specified
on page19.
WARNING
POTENTIAL HAZARD
Operating this ATV with improper modifications.
WHAT CAN HAPPEN
Improper installation of accessories or modification of this
vehicle may cause changes in handling which in some
situations could lead to an accident.
HOW TO AVOID THE HAZARD
Never modify this ATV through improper installation or use of
accessories. All parts and accessories added to this vehicle
should be genuine Polaris Industries Inc. or equivalent
components designed for use on this ATV; and should be
installed and used according to instructions. If you have
questions, consult an authorized Polaris ATV dealer.
40
SAFETY
Operator Safety
WARNING
POTENTIAL HAZARD
Overloading this ATV or carrying or towing cargo improperly.
WHAT CAN HAPPEN
Could cause changes in vehicle handling which could lead to an
accident.
HOW TO AVOID THE HAZARD
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
greater distance for braking.
Always follow the instructions in the Owner’s Manual for carrying
cargo or pulling a trailer. See pages 66 through 68.
WARNING
POTENTIAL HAZARD
Riding on frozen lakes and rivers.
WHAT CAN HAPPEN
Severe injury or death can result if the ATV and/or the operator
break through the ice.
HOW TO AVOID THE HAZARD
Never ride your ATV on a frozen body of water before you are
sure the ice is thick enough and sound enough to support the
machine and its operator, as well as the force that is created by
a moving vehicle.
41
SAFETY
Operator Safety
WARNING
POTENTIAL HAZARD
Improperly operating over obstacles.
WHAT CAN HAPPEN
Could cause loss of control or a collision. Could cause the ATV
to overturn.
HOW TO AVOID THE HAZARD
Before operating in a new area, check for obstacles.
Use extreme caution when riding over large obstacles, such as
large rocks or fallen trees.
If you cannot avoid obstacles, always follow proper procedures
as described in the Owner’s Manual.
WARNING
POTENTIAL HAZARD
Skidding or sliding.
WHAT CAN HAPPEN
You may lose control of the ATV.
You may also regain traction unexpectedly, which may cause the
ATV to overturn.
HOW TO AVOID THE HAZARD
On slippery surfaces, such as ice, go slowly and be very
cautious in order to reduce the chance of skidding or sliding out
of control.
42
SAFETY
Operator Safety
WARNING
After a rollover or an accident, have a qualified service dealer
check the complete machine including, but not limited to, brakes,
throttle and steering for possible damage.
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
overturns and loss of control which could result in severe injury
or death.
CAUTION
Keep combustible materials away from exhaust system. Fire
may result.
43
CONTROLS AND FEATURES
Controls
Engine Electrical Switches
3
1
2
WARNING
Activating the override button while throttle is open can cause loss
of control resulting in severe injury or death.
1. Override Switch (Reverse Speed
Limiter) - This vehicle is equipped
OFFOFF
with a reverse speed limiter
system. To obtain additional power
while backing up, depress the
override button. NOTE: The
override switch also allows
activation of AWD (All Wheel
Drive) in reverse, if the AWD switch is on. When not in reverse the
switch also acts as the “mode button” for the instrument cluster.
2. Main Switch - 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.
3. Engine Stop Switch - The engine will not start or run when the
switch is in its “off” position. Its purpose is to provide the
operator with a quick means of engine shutdown in case of stuck
throttle or other emergency. NOTE: Both the main switch and the
emergency engine stop switch shut off all electrical power to the
entire vehicle including lights. To stop the engine, slide the stop
switch right or left to the “off” position.
44
3
RUN
CONTROLS AND FEATURES
Controls
Engine Throttle and Choke
WARNING
Do not start or operate an ATV with sticking or improperly
operating throttle controls. A stuck or improperly operating
throttle could cause an accident resulting in severe injury or
death.
Always contact your dealer for service repairs whenever throttle
problems arise.
Failure to check or maintain proper operation of the throttle
system can result in the throttle lever sticking during riding and
cause an accident.
Always check the lever for free movement and return before
starting the engine and occasionally during riding.
Throttle Lever
Engine speed and vehicle
movement are controlled by
pressing the throttle lever.
The throttle lever (1) is spring
loaded and engine speed
returns to idle when the lever
is released.
This vehicle is equipped with
a Polaris Electronic Throttle
Control (ETC) which is
designed to reduce the risk of
a frozen or stuck throttle. In the event the throttle cable should stick in
an open position, the engine will stop and power to the rear wheels will
cease when the operator releases the throttle lever.
1
Choke
Refer to the engine starting procedure on page 64 for correct choke and
throttle settings during starting.
45
CONTROLS AND FEATURES
Controls
Brakes
The front and rear brakes are applied by squeezing the left side brake
lever toward the handlebar. The front and rear brakes are hydraulically
activated disc type brakes which are activated by one lever only.
Always test brake lever travel and reservoir fluid level before riding.
When squeezed, the lever should feel firm. Any sponginess would
indicate a possible fluid leak or low master cylinder fluid level which
must be corrected before riding. Contact your dealer for proper
diagnosis and repairs.
WARNING
Never operate the ATV with a spongy feeling brake lever.
Operating the ATV with a spongy brake lever can result in loss of
braking. Loss of braking could cause an accident.
46
CONTROLS AND FEATURES
Controls
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.
Front and Rear Brakes
The brake fluid in the master
cylinder, which is located on the
left handlebar, should be checked
before each ride. The fluid level
can be seen through an indicator
window (1) 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 the the handlebars straight.
If the fluid level is low add DOT 3
(PN 2870990) only.
4
WARNING
Once a bottle of brake fluid is opened, use what is necessary and
discard the rest. Do not store or use a partial bottle of brake fluid.
Brake fluid is hygroscopic, meaning it rapidly absorbs moisture
from the air. This causes the boiling temperature of the brake fluid
to drop, which can lead to early brake fade and the possibility of
severe injury.
47
CONTROLS AND FEATURES
Controls
Parking Brake
WARNING
Always check to be sure that the parking brake has been
disengaged before operating the ATV. An accident could result
causing severe injury if the parking brake is left on while the ATV
is operated.
Setting the Parking Brake
1. Put the vehicle gear selector
into park.
2. Squeeze the left hand brake
lever two or three times and
hold it.
3. Push the park brake lock (2)
into the notches on the master
cylinder body. Release the
brake lever.
4. To release the parking brake
lock, squeeze the brake lever.
It will return to its released
position.
2
Important Safeguards
The parking brake may relax when left on for a long period of time.
This could cause an accident.
Do not leave the vehicle on a hill depending on the parking
brake for more than five minutes.
Always put the gear selector in park and block the downhill side of
the wheels if leaving the ATV on a hill or park the ATV in a side
hill position.
48
CONTROLS AND FEATURES
Controls
Foot Brake
WARNING
Use caution when applying the foot brake. Do not aggressively
apply the foot brake when going forward or the rear wheels may
skid and slide sideways causing loss of control.
1
Your Polaris ATV has a foot brake (1) provided as a safety feature. It
is located on the inside of the right floor board and is operated by the
right foot. It is intended as a backup to the main brake system,
especially if the main system becomes inoperative.
If the rear wheels slide, reduce brake pedal pressure to brake the rear
wheels without skidding. Aggressively applying the rear brake when
backing down a hill may cause rear tip over.
Brake Fluid Level
It will be necessary to check the brake fluid level for the foot brake.
The reservoir is located under the RH rear cab. The fluid should be
kept between the maximum and minimum marks.
49
CONTROLS AND FEATURES
Controls
Fuel System
The fuel tank filler cap (1)
is located directly behind
the handlebar. Refer to
vehicle specifications on
page 7 for tank capacity.
Use either leaded or
unleaded gasoline with a
minimum pump octane
number of 87 (R+ M/2)
octane.
The fuel valve is located on
the left side panel and has
three positions:
OFF: For vehicle storage
and whenever transporting.
ON: For normal operation.
RES: For reserve supply in
the event of main supply
exhaustion.
NOTE: There is about a 7
to 10 mile (11.2 to 16 km)
range on reserve gas.
Always refill the gas tank
as soon as possible after
having used the reserve
supply.
Always return valve to
“on” position after
refueling machine.
OFF
1
RES
ON
Fuel Filter
The Polaris ATV is equipped with an in-line fuel filter.
This filter should be replaced by your dealer after every 100 hours of
operation or annually. Do not attempt to clean the fuel filter.
50
CONTROLS AND FEATURES
Controls
Fuel Safety
WARNING
Gasoline is highly flammable and explosive under certain
conditions.
Always exercise extreme caution whenever handling gasoline.
Always refuel with the engine stopped and outdoors or in a well
ventilated area.
Do not smoke or allow open flames or sparks in or near the
area where refueling is performed or where gasoline is stored.
Do not over fill the tank. Do not fill the tank neck.
If you get gasoline on your skin or clothing, immediately wash it
off with soap and water and change clothing.
Never start the engine or let it run in an enclosed area. Gaso-
line powered engine exhaust fumes are poisonous and can
cause loss of consciousness and death in a short time.
Shut off fuel valve whenever the ATV is stored or parked.
WARNING
The engine exhaust from this product con-
tains chemicals known to cause cancer,
birth defects or other reproductive harm.
51
CONTROLS AND FEATURES
Controls
Automatic Transmission Gear Selector
The transmission gear selector is located
on0 the right side of the vehicle directly
above and forward of the engine and has
five positions: high, low, neutral; reverse,
and park.
To shift into “High” or “Park”, you
must first depress the foot brake to
activate the High/Park lock out
mechanism.
When shifting out of “High” or “Park”, it is
not necessary to depress the brake.
NOTE: To extend belt life, use low
forward gear in heavy pulling situations
and in situations where you are operating
below 7 miles per hour for extended
periods of time.
H
L
N
R
P
CAUTION
To change gears, stop the vehicle and with the engine idling,
move the lever to the desired gear. Depress the foot brake if
shifting into high or park. Shifting gears with the engine speed
above idle or while the vehicle is moving could cause transmission
damage.
Always place the transmission in park with the parking brake locked
whenever the vehicle is left unattended.
GENERAL RANGE OPERATION GUIDELINES:
Low Range Heavy pulling, basic operational
speeds less than 7 MPH, riding
through rough terrain (swamps, mountains, etc.), low ground speeds.
High RangeHigh ground speeds, speeds above 7
MPH.
52
CONTROLS AND FEATURES
Important Safeguards
Always back slowly avoiding excessive speed and do not use the
reverse speed override switch system unless additional power is
required for vehicle movement.
Avoid turning at sharp angles in reverse.
Avoid backing on steep inclines.
Light Switches and Indicator Lights
WARNING
This ATV is not equipped with highway approved lighting. This
ATV is designed for off-road use only and must not be ridden on
streets or highways. Use caution and drive at reduced speeds in
conditions of reduced visibility such as fog, rain and darkness.
Oil Pressure Switch
Some 2002 Sportsman
700 ATVs were
produced without an oil
pressure switch as
standard equipment.
If your model has this
switch, it will be
located on the LH side
of the engine next to
the oil filler tube. It is
not to be confused with
the engine temperature
switch that is located
on the same side but
higher up on the
engine.
If the oil pressure
switch is not installed
on your engine, the oil
pressure warning is not
active and the
diagnostic mode
feature is not valid.
Engine
Temperature
Switch
Oil Pressure
Switch
53
CONTROLS AND FEATURES
Features
Exclusive AWD System (All Wheel Drive)
Polaris 4 wheel drive ATVs are
equipped with a unique, Polaris
exclusive, All Wheel Drive
(AWD) system which is
activated by a switch (1) on the
right handlebar. When the
switch is “off” the ATV is in 2
wheel drive at all times. When
the switch is “on” the ATV is in
All Wheel Drive and the AWD
indicator(2) will light.
When in AWD, the front
wheels will automatically
engage anytime the rear wheels
lose traction. When the rear
wheels regain traction, the front
wheels will automatically
disengage.
NOTE: The override switch
also allows activation of All
Wheel Drive (AWD) in reverse,
if All Wheel Drive switch is
on.
There is no limit to the length of time the vehicle may remain in All
Wheel Drive.
The All Wheel Drive switch may be turned on or off while the vehicle
is moving. If the switch is turned off when the front hub is driving it
will not release until the rear wheels regain traction. To protect the
front drive system, the AWD will not engage if the engine is running
higher than 3100 RPM. Once enabled, the AWD system will work at
any RPM.
1
2
CAUTION
Do not switch on All Wheel Drive if the rear wheels are spinning.
This may cause severe drive shaft and hub damage.
54
CONTROLS AND FEATURES
Features
Exclusive AWD System (All Wheel Drive)
Engage the All Wheel Drive switch before getting into conditions
where front wheel drive may be needed. If the rear wheels are
spinning, release the throttle before turning the All Wheel Drive switch
on. NOTE: If the instrument cluster is not registering a proper gear
indication, AWD can still be enabled by pressing the mode/override
button.
Disengaging Wheel Hubs
When backing or while in All Wheel Drive and then going forward
again, the AWD hub may remain engaged. If the hub remains engaged
it can be disengaged by stopping, shifting to and moving in reverse.
Then proceed in forward again.
NOTE: If the hub remains engaged after following these instructions
return the ATV to your dealer for service.
Switches
The light switch is located on the left hand handlebar. In addition to
turning the lights on and off, it also switches the lights from Hi to Lo
on models equipped with Hi-Lo beams. NOTE: The lights will not
work unless the key is in the on position and shut off switch is in the
“run” position.
55
CONTROLS AND FEATURES
Features
Instrument Cluster
Your Sportsman 700 is equipped with an instrument cluster which
senses vehicle speed from the right hand 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 at
approximately 7 to 9 mph. Refer to page 44 for additional information.
3
2
1
1Rider Information Center
2Speedometer needle - in addition to depicting vehicle speed, this
needle will flash indicating a fault condition.
3Speedometer
CAUTION
Do not wash the instrument cluster with a high pressure washer.
Water under high pressure may enter the instrument cluster and
cause damage to the electronic components. Wash the unit by
hand or with a garden hose using mild soap. Do not use alcohol to
clean the instrument cluster. Do not allow gasoline to remain on
the instrument cluster.
56
CONTROLS AND FEATURES
Features
Rider Information Center
The rider information center is located in the lower portion of the
instrument cluster.
1Gear Indicator -
As the shift lever
is moved, this
will indicate the
gear the machine
is in:
H = High Range
L = Low Range
N = Neutral
R = Reverse
P = Park
E or blank = Error
- Most of the time,
this error message
will indicate you
are inbetween
gears. It can,
however, also
indicate the
transmission
switch is broken.
2 High Engine Coolant Temperature
3Low Oil Pressure
4Hour Meter
5Service Interval
6Low Battery and over voltage
NOTE: All segments of the rider information center will light up for
2.5 seconds at start-up.
1
2
4
3
5
6
57
CONTROLS AND FEATURES
Features
Rider Information Center
The rider information center has 4 standard modes:
Mode 1 - Odometer
Mode 2 - Tripmeter
Mode 3 - Total Service Hours
Mode 4 - Programmable service interval
The reverse override button which is found on the LH 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
This will record the amount of miles the ATV travels.
Mode 2 -Trip Meter
To reset the trip meter, select the tripmeter mode. Press and hold the
mode button (override button) until the total changes to “0” . NOTE:
In the Rider Information Center, the trip meter is displayed with a
decimal point, the odometer is displayed without a decimal point.
Mode 3 - Hour Meter
This mode logs the total hours the engine has been in operation.
58
CONTROLS AND FEATURES
Features
Rider Information Center
Mode 4 - Programmable Service Interval
The purpose of the programmable service interval is to provide the
consumer and their dealer with a convenient way to schedule routine
maintenance. When your vehicle leaves the factory, this feature is
turned “OFF”. You must enable this feature if you intend to use it to
track maintenance requirements.
The service interval mode operates by service hours. To set the hours,
press and hold the mode/override button until the wrench icon flashes.
When it begins to flash, release the button. At this point, each time the
button is pressed, the setting will increase by one hour. Pressing and
holding the button will allow the numbers to escalate much faster.
When the desired time increment is displayed, release the button and
wait for the wrench to stop flashing. When the wrench stops blinking,
your service hours are set. NOTE: If you scroll past the intended
number, hold the button down until the count turns over to “0”. At this
point you can re-attempt to set the number.
Once the service interval mode is set, it will count down to “0”
according to the hours your engine is running. When the counter times
out at “0”, the wrench icon will flash quickly for 5 seconds every time
the vehicle is started as a reminder that the next periodic maintenance
is due.
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.
59
CONTROLS AND FEATURES
Features
Rider Information Center
Diagnostic Mode
CAUTION
The diagnostic mode is for informational purposes only. Your
dealer is fully equipped with the knowledge and special tools
required to keep your machine running. Please return your ATV to
your dealer for all major repairs.
To enter the diagnostics mode:
1. Turn the key switch off and wait 20 seconds.
2. Set the park brake and shift the transmission to neutral.
3. Hold the mode/reverse override button as you turn the key switch
on.
The initial screen
displayed looks
similar to this
illustration and is
referring to the
software version
currently installed in
your machine. This
information is only
briefly displayed.
Use the
mode/reverse
override button to
toggle through the
diagnostic screens.
The first screen
indicates battery
voltage.
60
CONTROLS AND FEATURES
Features
Rider Information Center
The second screen
provides a full
diagnostic
indication of the
entire oil pressure
electrical circuit.
Along with the
letters PrSSr, there
will be a box on
the LH side. If the
box is high, the
pressure is normal.
If the box is low,
the pressure is low.
Screen three is the
tachometer for
setting idle speed.
If this needs
adjustment, please
contact your
dealer.
As long as you are
in the diagnostic
mode, the wrench
icon will remain
lit.
To leave the diagnostic mode, either shift the machine out of neutral or
turn the keyswitch off and on. NOTE: Any movement of the tires will
also take the machine out of the diagnostic mode.
Auxiliary Power Outlet
Auxiliary power outlets provide 12V power for operating accessories
such as hand held spot lights and is located on the front headlight pod.
Accessory outlets are available for all models. Contact your Polaris
dealer for more information.
61
OPERATION
Pre Ride Inspection
WARNING
You must inspect your ATV each time before riding to ensure it is
in proper working order. If proper inspection is not done, severe
injury or death could result.
Use the following checklist to verify your machine is in proper
working order each time you ride.
Item/Inspection Procedure
1. Tires - check condition and pressures
2. Fuel and oil tanks - fill both tanks to their proper levels
3. All brakes - check operation, adjustment and fluid level (includes
foot 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 vehicle for any damaged components
or loose nuts/bolts or fasteners
11. Operators helmet, goggles and clothing
12. Engine coolant - check for proper level at the recovery bottle
62
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 tanks full of
gasoline. No single action on your part is as important as a proper
break in period. Careful treatment of a new engine will result in more
efficient performance and longer life for the engine. Perform the
following procedures carefully.
CAUTION
Use only Polaris Premium 4 All Season synthetic oil, or API
certified “SH” oil. Never substitute or mix oil brands. Serious
engine damage and voiding of warranty can result.
Do not operate at full throttle or high speeds for extended periods
during the first three hours of use. Excessive heat can build up
and cause damage to close fitted engine parts.
1. Fill fuel tank with
either unleaded or
leaded fuel which has
a minimum pump
octane number of 87=
(R+ M)/2.
2. Check oil reservoir level indicated on dipstick. Add oil if
necessary.
3. Drive slowly at first. Select an area which is open and will give
you room to familiarize yourself with vehicle operation and
handling.
4. Vary the throttle positions. Do not operate at sustained idle or
sustained high speed.
5. Perform regular checks on fluid levels, controls and all important
areas on the vehicle as outlined earlier on the daily pre-ride
inspection checklist found on page 62.
6. Pull only light loads.
7. Break in oil and filter. Change at 20 hours or 200 miles.
SAFE
ADD 8 OZ
63
OPERATION
Starting the Engine
Procedure for Starting a Cold Engine
WARNING
Never run an engine in an enclosed area. Carbon monoxide
exhaust gas is poisonous and can cause severe injury or death.
Always start engines outdoors.
CAUTION
You must allow your vehicle adequate warm up time before
operating or engine damage could result.
1. Place the transmission in
neutral or park and reset the
parking brake.
2. Turn the fuel tank valve to ON.
3. Sit on the vehicle.
4. Pull the choke out all the way.
5. Turn the engine stop switch to
RUN.
6. Turn the ignition key past the
“ON” position to engage the
starter.
NOTE: the choke is on “FULL” when the knob is pulled out all the
way. The choke is “OFF” when the knob is pushed in. This is a
variable choke and can be adjusted gradually, depending on how much
choke is needed for starting.
7. Do not press the throttle while starting the engine.
8. Activate the starter for a maximum of five seconds, releasing the
key when the vehicle starts. If engine does not start, release the
starter and wait five seconds; then activate the starter for another
five seconds. Repeat this procedure until engine starts.
64
OPERATION
Starting the Engine
After the Engine Starts
1. If the engine slows or stops, use of the choke at half way in will
allow proper engine warm up.
2. Vary the engine RPM slightly with the throttle to aid in warm up
until the engine idles smoothly. Then push the choke all the way
in.
Cold Weather Operation
Polaris offers an engine heater kit for cold operation.
If you use your ATV all year round, it is important to check your oil
level frequently. A rising oil level could indicate the accumulation of
water in the bottom of the oil tank. Water in the bottom of the tank can
lead to engine damage and must be drained.
Water accumulation increases as outside temperature decreases.
The cold weather kit not only reduces moisture accumulation, but the
heater will provide quicker warm-ups and easier starting.
See your dealer for more information on cold weather operation and if
the heater kit will enhance your cold weather operation.
65
OPERATION
Carrying Loads
Your ATV has been designed to carry a certain amount of load.
CARGO WEIGHT should be evenly distributed (1/3 on the front and
2/3 on the rear) and mounted as low as possible. When operating over
rough or hilly terrain, reduce speed and cargo to maintain stable
driving conditions.
Maximum trailer weight - 1500 (680 kg) on level ground only with a
maximum vertical hitch weight of 150 lbs. (68.04 kg). NOTE: The
rear rack capacity and tongue weight should not exceed 180 lbs.
Maximum grade while trailer towing - 15°. Do not tow any trailer on a
grade steeper than 15° (850 lbs on grades up to 15° ).
Your machine is equipped with a front rack, take care when loading.
Improper loading of the front rack can obstruct the headlight beam,
reducing night visibility. Do not obstruct the headlight beam with
cargo.
Use of low forward gear is recommended in heavy pulling situations to
extend belt life.
66
OPERATION
Carrying Loads
WARNING
Correct loading of this vehicle is necessary to maintain proper
stability and operating characteristics. Overloading or incorrect
positioning of the load affects the vehicle’s turning, stopping
distance and stability. Failure to follow loading requirements
could cause severe injury or death.
2/3 of Load on
Rear Rack
1/3 of Load on
Front Rack
Important Safeguards
To reduce risk of injury or machine damage when carrying loads, read
and follow the warnings listed below:
REDUCE SPEED AND ALLOW GREATER DISTANCE
FOR BRAKING WHEN CARRYING CARGO.
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 tip over.
HEAVY LOADS CAN CAUSE BRAKING AND CONTROL
PROBLEMS. Use extreme caution when applying brakes
with a loaded vehicle. Avoid terrain or situations which may
require backing downhill.
ALL LOADS MUST BE SECURED BEFORE MOVING
VEHICLE. Unsecured loads can create unstable operating
conditions, which could result in loss of control of the vehicle.
67
OPERATION
Carrying Loads
LOADS MUST BE CARRIED 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. When cargo loads are carried high on the
racks, the weight of the loads must be reduced to maintain
stable operating conditions.
OPERATE ONLY WITH STABLE AND SAFELY AR-
RANGED LOADS. When handling off-centered loads which
cannot be centered, securely fasten load and operate with extra caution. Always attach the tow load to the hitch point
designated for your ATV.
EXTREME CAUTION MUST BE USED when operating
with loads extending over the rack sides. Stability and maneuverability may be adversely affected, causing the machine
to overturn.
DO NOT BLOCK THE FRONT HEADLIGHT BEAM when
carrying loads on the front rack.
DO NOT TRAVEL FASTER THAN THE REC-
OMMENDED 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.
68
NOISE EMISSION CONTROL
SYSTEM REGULATION
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 ARE THE
ACTS LISTED BELOW INCLUDE BUT ARE NOT LIMITED TO
THE FOLLOWING:
1. Removal or alteration or the puncturing of the muffler or any engine
component which conducts removal of engine exhaust gases.
2. Removal or 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
Remember, exhaust system components are very hot during and after use of ATV. Serious burns can result if hot
components are touched.
Do not touch exhaust system components. Serious burns can re-
sult.
Be especially careful when traveling through tall grass. The poten-
tial for fire exists.
USFS Approved Spark Arrestor
Most Polaris ATVs have mufflers that were tested and approved in
accordance with the USFS Forest Service Standard 5100-1A.
69
RIDING
Pre Ride Inspection
WARNING
You must inspect your ATV each time before riding to ensure it is
in proper working order. If proper inspection is not done, severe
injury or death could result.
Use the following checklist to verify your machine is in proper
working order each time you ride.
Item/Inspection Procedure
1. Tires - check condition and pressures
2. Fuel and oil tanks - fill both tanks to their proper levels
3. All brakes - check operation, adjustment and fluid level (includes foot
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 vehicle for any damaged components or
loose nuts/bolts or fasteners
11. Operators helmet, goggles and clothing
12. Engine coolant - check for proper level at the recovery bottle
70
RIDING
Safe Riding Tips
Riding Position
1. Sit upright with both feet on the footrests and both hands on the
handlebars.
2. After starting the engine and allowing it to warm up, shift the
transmission into gear.
3. Check your surroundings and determine your path of travel.
4. Release the parking brake.
5. Slowly depress the throttle with your right thumb and begin 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.
71
RIDING
Safe Riding Tips
Making Turns
Practice making turns at slow speeds.
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.
The same leaning technique should be used for turning in reverse.
WARNING
Avoid turning at sharp angles in reverse as tipover and severe
injury may result.
72
RIDING
Safe Riding Tips
Riding on Slippery Surfaces
Whenever riding on slippery surfaces such as wet trails or
loose gravel, or during cold freezing weather, special attention must be paid to prevent vehicle turnover. Always:
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 in the direction of the skid
and shifting your body weight forward.
4. Driving with All Wheel Drive (All Wheel Drive) engaged can assist in
controlling the vehicle in slippery areas.
5. Never apply brakes during a skid. Complete loss of ATV control can
result.
6. Do not operate on excessively slippery surfaces if possible to avoid.
7. Always reduce speed and use additional caution.
CAUTION
Severe damage to drive train may occur if the Demand Drive is
engaged while the wheels are spinning.
WARNING
Failure to exercise care when operating the ATV on slippery
surfaces can be dangerous.
Loss of tire traction and vehicle control can result in an accident,
including an overturn.
73
RIDING
Safe Riding Tips
Traveling Uphill
25 Maximum
WARNING
Exercise extreme caution when traveling in hilly terrain. Braking
and handling are greatly affected. Loss of vehicle control or
overturning of the ATV could occur causing severe injury or death.
4. Proceed at a steady rate of speed and throttle opening.
5. Remain alert and be prepared to take emergency action. This may
include quick dismounting of the ATV.
74
Safe Riding Tips
Sidehilling
RIDING
Sidehilling your ATV is one of the most dangerous types of
riding and should be avoided if possible. In the event you do
enter into a situation where sidehilling is necessary, always:
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.
If vehicle begins to tip, quickly turn the front wheel downhill, if
possible, or dismount on the uphill side immediately!
WARNING
Improperly crossing hills or turning on hills can be dangerous.
Loss of vehicle control or overturning of the ATV could occur
causing severe injury or death.
75
RIDING
Safe Riding Tips
Traveling Downhill
Whenever descending a hill, always:
1. Drive directly downhill.
2. Transfer your weight to the rear of the vehicle.
3. Slow down.
4. Apply the brakes slightly to aid in slowing.
Familiarize yourself with the foot brake and its use in the event loss of
normal service brakes occurs.
WARNING
Do not travel at excessive speeds. It is dangerous and can
cause loss of vehicle control and tipping, resulting in severe injury
or death.
76
RIDING
Safe Riding Tips
Turning Around on a Hill
8’
Uphill
If the ATV stalls while climbing a hill, never back it down the
hill! One maneuver which can be used when it is necessary
to turn around while climbing a hill is the K-turn.
1. Stop and lock the parking brake while maintaining body weight
uphill.
2. Leave transmission in forward and shut off engine.
3. Dismount on left or uphill side of ATV.
4. Staying uphill of ATV, turn handlebars full left (while facing front
of ATV).
5. While holding service brake, release parking brake lock and slowly
allow ATV to roll around to your right until ATV is pointing across
the hill or slightly downward.
6. Lock the parking brake and remount ATV from the uphill side,
maintaining body weight uphill.
7. Restart engine with transmission still in forward, release parking
brake, and proceed slowly, controlling speed with the service
brake, until ATV is on reasonably level ground.
WARNING
Avoid climbing steep hills. Loss of vehicle control or overturning of
the ATV could occur resulting in severe injury or death.
77
RIDING
Safe Riding Tips
Crossing Streams
Your Polaris ATV can operate through water up to maximum
recommended depths reaching the footrests. Before fording
streams always:
1. Determine water depths and current.
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 is normal.
Avoid operating the ATV through deep or fast flowing water. If
you cannot avoid water which exceeds the recommended maximum depth, go slowly, balance your weight carefully, avoid sudden movements, maintain a slow and steady forward motion. Do
not make sudden turns or stops and do not make sudden throttle
changes.
NOTE: After running the vehicle in water, it is critical your machine
is serviced as outlined in the maintenance chart beginning on page 82.
The following areas need special attention: engine oil, transmission
oil, front and rear gearcases, and all grease fittings.
If your vehicle becomes immersed, and it is impossible to take it to a
dealer before starting, follow the steps described on page 121. It is still
important the vehicle be serviced by your dealer at the first
opportunity.
78
RIDING
Safe Riding Tips
Trail Obstacles
Keep Alert!
Look ahead and learn to read the trail as you ride. Stay on the right
side of the trail, if possible, and be constantly alert for hazards such as
logs, rocks and low hanging branches.
WARNING
Not all obstacles are visible. Travel with caution on trails.
severe injury or death can result if your machine comes in
contact with a hidden obstacle.
79
RIDING
Safe Riding Tips
Backing Up
1. Avoid backing up on steep inclines.
2. Always 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.
6. Never activate override button while throttle is open. Loss of
control may result.
NOTE: Most Polaris ATVs are equipped with a reverse speed limiter.
The override button should be used with caution as rearward vehicle
speed is greatly increased. Do not operate at wide open throttle. Only
open the throttle enough to maintain a desired speed.
CAUTION
Opening the throttle more than required may cause excessive fuel
to build in the exhaust, resulting in engine popping and/or engine
damage.
80
RIDING
Safe Riding Tips
Parking on an Incline
Whenever the Vehicle is Parked
1. Turn the engine off.
2. Place the transmission in park.
3. Set the parking brake.
4. Avoid parking on an incline. If it is necessary to park on an
incline, always block the rear wheels on the down hill side as
shown above.
5. Shut off fuel supply.
81
MAINTENANCE AND LUBRICATION
Periodic Maintenance Schedule
Careful periodic maintenance will help keep your vehicle in the safest,
most reliable condition. Inspection, adjustment and lubrication
intervals of important components are explained in the following chart
on the following pages.
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. If you are not familiar with
safe service and adjustment procedures, have a qualified dealer perform
these operations.
Inspect, clean, lubricate, adjust or replace parts as necessary. NOTE:
Inspection may reveal the need for replacement parts. Always use
genuine Polaris parts available from your Polaris dealer.
Service and adjustments are critical. If you are not familiar with safe
service and adjustment procedures, have a qualified dealer perform
these operations.
CAUTION
Due to the nature of the adjustments marked with a on the
following chart, it is recommended that service be performed by an
authorized Polaris dealer.
More often under severe use, such as dirty or wet conditions to
purge water or dirt contamination from grease fittings and other
critical components.
Emission Control System Service (California - 4-Cycle) NOTE:
Some 4-Cycle models may have an additional California -only
emissions warranty.
ply Polaris dielectric
grease to connector when
replaced
ply Polaris dielectric
grease to socket when replaced
sary
83
MAINTENANCE AND LUBRICATION
Periodic Maintenance Schedule
CAUTION
Due to the nature of the adjustments marked with a on the
following chart, it is recommended that service be performed by
an authorized Polaris dealer.
More often under severe use, such as dirty or wet conditions to
purge water or dirt contamination from grease fittings and other
critical components.
Emission Control System Service (California - 4-Cycle) NOTE:
Some 4-Cycle models may have an additional California -only
emissions warranty.
ItemHours or
Miles
Transmission Oil
Level
Battery20 hrsMonthlyCheck Terminals/clean/
Engine breather filter
(4-cycle)
Brake pad wear20 hrsMonthlyInspect periodically
Front and Rear Gear-
case Oil (shaft drive)
General Lubrication50 hrs3
Engine Oil - Level/
Change (4-Cycle)
20 hrsMonthlyInspect monthly; change
20 hrsMonthlyInspect-replace annually
100 hrsMonthlyCheck monthly and
100 hrs /
1000
miles
WhenRemarks
annually
check fluid level
and as needed
change annually
Lubricate all fittings, pivots,
months
6
months
cables, etc.
Check Level Daily; Break
in Service at 1 month.
Change oil more often in
cold weather use.
84
MAINTENANCE AND LUBRICATION
Periodic Maintenance Schedule
ItemHours or
Miles
Oil Filter(4-Cycle)100 hrs /
1000
miles
Engine breather
hose
(4-cycle)
Carburetor Float
Bowl
Throttle Cable/ETC
Switch
Choke (Enricher)
Cable
Coolant strength/
pressure test system
Drive belt50 hrs6
Steering50 hrs6
Front Suspension50 hrs6
Rear Suspension50 hrs6
Spark Plug100 hrs12
Rear Axle50 hrs6
100 hrs6
50 hrs6
50 hrs6
50 hrs6
100 hrs6
WhenRemarks
6
months
months
months
months
months
months
months
months
months
months
months
months
Replace with oil change
Inspect
Drain bowl periodically and
prior to storage
Inspect-adjust, lubricate,
replace if necessary; preride inspection item
Inspect, lubricate, replace
if necessary
Inspect strength seasonally; pressure test system
annually
Inspect, replace if necessary
Inspect daily, lubricate
Inspect-lubricate, tighten
fasteners
Inspect, tighten fasteners
Inspect-replace if necessary
Inspect bearings, Lube
85
MAINTENANCE AND LUBRICATION
Periodic Maintenance Schedule
CAUTION
Due to the nature of the adjustments marked with a on the
following chart, it is recommended that service be performed by
an authorized Polaris dealer.
More often under severe use, such as dirty or wet conditions to
purge water or dirt contamination from grease fittings and other
critical components.
Emission Control System Service (California - 4-Cycle) NOTE:
Some 4-Cycle models may have an additional California -only
emissions warranty.
ItemHours or
Miles
Ignition Timing100 hrs12
Fuel System100
hours
Fuel Filter100 hrs12
Radiator100 hrs12
Cooling System
hoses
Spark arrestor100 hrs12
Clutches (drive and
driven)
100 hrs12
100 hrs12
WhenRemarks
months
12
months
months
months
months
months
months
Inspect and adjust as
needed
Check for leaks at tank
cap, lines, fuel valve, filter,
pump and carburetor. Replace lines every two
years.
Replace annually
Inspect/clean external surface
Inspect
Clean out
Inspect, clean
86
MAINTENANCE AND LUBRICATION
Periodic Maintenance Schedule
ItemHours or
Miles
Engine Mounts100 hrs12
Valve Clearance100 hrs12
Brake fluid200 hrs24
Front wheel bearings300 hrs36
Idle SpeedAs Re-
quired
Toe adjustmentAs re-
quired
Headlight AimAs re-
quired
WhenRemarks
months
months
months
months
As Re-
quired
As re-
quired
As re-
quired
Inspect
Inspect/Adjust
Change every two years
Inspect, replace if necessary
Adjust
Periodic inspection, adjust
when parts are replaced
Adjust if necessary
87
MAINTENANCE AND LUBRICATION
Lubrication Recommendations
ItemLube RecMethodFrequency*
(1)Engine OilPolaris
Premium
4 Synthetic 0W40
(2) Brake
Fluid
(3) Transmission Oil
(4) Front
Gearcase Oil
(5) Rear
Gearcase Oil
(6) Front
Prop Shaft
U-joints
(7) Front
Propshaft
Yoke
DOT 3
Only
Polaris
Premium
Synthetic
gear case
lube
Premium
Hub Lube
GL5
80-90
Weight
Gear
Lube
Grease+Locate Fittings and
Grease+Locate fittings and grease
Add to proper level on dipstick. See page 96.
Maintain level between fill
lines. See page 47.
See Page 98Change
See Page 99Change
Grease
- 3 pumps maximum
Check level
daily.
As required;
change every
two years or
200 hours
annually or at
100 hours
annually or at
100 hours
Change
Annually or
at 100 hours
Every 3
months or 50
hours
Every 3
months or 50
hours
88
MAINTENANCE AND LUBRICATION
Lubrication Recommendations
(4) Front Gear Case
Fill plug
(5) Rear Gear Case
(6) Front Prop Shaft
(U-Joints)
(3) Transmission
(plug)
Fill plug
(7) Propshaft Yoke
89
MAINTENANCE AND LUBRICATION
Lubrication Recommendations
(8) Front
Drive Axle (U
Joint) (AWD
Models)
(9) Ball Joint
(10) Front A
Arm Pivot
Shaft
(11) Upper
steering Post
Bushing
(12) Upper
Control ArmsGrease
(13) Lower
Control ArmsGrease
(14) Rear
Wheel Hub
Bearing Carrier
(15) Rear
Anti-Roll BarGrease
More often under severe use, such as wet or dusty conditions.
**Polaris Premium all Season Grease or grease conforming to NLGI
No. 2, such as Conoco Superlube M or Mobilegrease Special.
+ Grease every 500 miles, or before long periods of storage or after
pressure washing, or after submerging in water. Always use Polaris
Premium U-Joint Lube for maximum service of these driveline
components (PN 2871515 3 oz.)(PN 2871551 14 oz.).
∆ When suspension action becomes stiff or after washing.
NOTE: Hours are based on 10 mph average.
Grease+ Locate grease fitting and
grease with grease gun.
Locate fitting on back side of
Grease
**
Grease
**∆
Grease
**
**∆
**∆
Grease
**∆
struts and grease with grease
gun.
Locate fitting on pivot shaft
and grease with grease gun.
Locate fitting on steering post
and grease with grease gun.
Locate fittings and greaseSemi-
Locate fittings and greaseSemi-
Locate fitting and greaseSemi-
Locate fitting and greaseSemi-
Every 3
months or
50 hours
Every 3
months or
50 hours
Every 3
months or
50 hours
Every 3
months or
50 hours
annually
annually
annually
annually
90
MAINTENANCE AND LUBRICATION
Lubrication Recommendations
(11) Steering
Post
Bushing
(10) Front A Arm
Pivot Shaft
Upper
(13) Lower Control
Arm
(8) Axle Cardan
Front Drive
(13) Lower Control
Arm
(15) Rear AntiRoll Bar
(12) Upper Control
Arm
(14) Rear Wheel
Hub Bearing
Carrier
91
MAINTENANCE AND LUBRICATION
Periodic Maintenance Record
Use the following chart to record periodic maintenance work:
Maintenance
Interval
Performed
First 5 Hrs.
25 Hrs.
50 Hrs.
75 Hrs.
100 Hrs.
Servicing
Date
Servicing
Dealer
or Person
Remarks
92
MAINTENANCE AND LUBRICATION
Engine Cooling System
Coolant Level
The recovery bottle(1), located on
the left side of the machine, must be
maintained between the minimum
and maximum levels indicated on
the recovery bottle.
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 the 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. 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.
To access the recovery bottle it is necessary to remove the left side
panel as described on page 130.
1
93
MAINTENANCE AND LUBRICATION
Engine Cooling System
WARNING
Never remove the pressure cap when the engine is warm or hot.
Escaping steam can cause severe burns. The engine must be
cool before removing the pressure cap.
Radiator Coolant Level Inspection
NOTE: This procedure is
only required 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 inspected
and coolant added if necessary.
To access the radiator pressure
cap:
Using the tool provided,
remove the four screws
securing front rack (1).
Remove front cover (2) by
placing your fingers under the
front of the cover and pulling
upward.
2
1
94
MAINTENANCE AND LUBRICATION
Engine Cooling System
NOTE: Use of a non-standard pressure cap will not allow the
recovery system to function properly. If the cap should need
replacement contact your dealer for the correct replacement part.
To insure that the coolant maintains its ability to protect the engine, it
is recommended that the system be completely drained every two years
and a fresh mixture of antifreeze and water be added.
Polaris recommends the use of Polaris Premium 60/40
anti-freeze/coolant or a 50/50 mixture of high quality aluminum
compatible anti-freeze/coolant and distilled water. 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.
Using a funnel, slowly add coolant as necessary through the radiator
filler neck.
95
MAINTENANCE AND LUBRICATION
Lubrication
4-Cycle Premium 4 Synthetic Lubricant
CAUTION
Use only Polaris Premium 4 All Season synthetic oil or API
certified “SH” oil. Never substitute or mix oil brands. Serious
engine damage and voiding of warranty can result.
Polaris Premium 4 All Season Synthetic engine oil has been specially
formulated for use in Polaris 4-cycle engines. It is a fully synthetic,
high performance, multi-viscosity oil designed to provide the ultimate
in lubrication performance and protection.
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. Its
exceptional frictional properties result in more efficient operation, more
power output, lower fuel consumption, and easier starting in cold
temperatures.
Although Polaris Premium 4 is the only oil recommended for use in
this engine, use of any API certified “SH” oil is allowable. Oil may
need to be changed more frequently if Polaris Premium 4 is not used.
You will also need to follow the manufacturers recommendations for
ambient temperature operation.
96
MAINTENANCE AND LUBRICATION
Lubrication
Oil and Filter Change
1. Place vehicle on a level surface.
2. Run engine two to three minutes until warm. Stop engine.
3. Clean area around drain plug.
4. Place a drain pan beneath engine crankcase and remove drain plug.
CAUTION: Oil may be hot. Do not allow hot oil to come into
contact with skin as serious burns may result.
5. Allow oil to drain completely.
6. Replace sealing washer on drain plug. NOTE: The sealing
surfaces on drain plug and crankcase should be clean and free of
burrs, nicks or scratches.
7. Reinstall drain plug and torque to 14 ft. lbs. (19 Nm).
8. Place shop towels beneath oil filter. Using an oil filter wrench,
turn filter counterclockwise to remove.
9. Using a clean dry cloth, clean filter sealing surface on crankcase.
10. Lubricate O-ring on new filter with a film of new engine oil.
Check to make sure the O-ring is in good condition.
11. Install new filter and turn by hand until filter gasket contacts the
sealing surface, then turn and additional 1/2 turn.
12. Remove dipstick and fill sump with 2 quarts (1.9 l) of Polaris
Premium 4 synthetic oil.
13. Place gear selector in neutral and set 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.
NOTE: Drain Plug Torque: 14 ft. lbs. (19 Nm); Oil Filter Torque: Turn
by hand until filter gasket contacts the sealing surface, then turn an
additional 1/2 turn.
97
MAINTENANCE AND LUBRICATION
Lubrication
Transmission Lubrication
The transmission fill plug is located on the right side of the machine
behind the propshaft shield or footwell.
The transmission lubricant level should be checked every six months or
1000 miles (1600 km), whichever comes first. Transmission oil should
be changed annually. With the ATV on a level surface, remove fill
plug (1) and check the lubricant level. Use the illustration and the chart
below to determine the correct fluid level. The correct transmission
lubricant to use is Polaris Premium Synthetic Gearcase Lubricant (PN
2871478).
Model
Sportsman 7001 5/8″13.5 (400)
Oil Level “A”Oil Fill Ounces (ml)
Transmission Oil Changing Procedure
1. Remove the
four screws
on the
footwell
and gently
pull
outward for
access.
2. Remove fill plug.
3. Remove transmission drain plug (2)
located on the bottom left hand side
and drain the oil. Catch and discard
used oil properly.
4. Clean and reinstall the drain plug
torque to 14 ft. lbs. (1.93 kg-m).
5. Add the correct amount of Polaris
Premium Synthetic Gearcase
Lubricant
until oil reaches the bottom of the
filler hole.
6. Check for leaks.
7. Reinstall footwell and screws
removed in step 1.
1
A
2
98
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